Three-dimensional nonwoven materials and methods of manufacturing thereof

ABSTRACT

Three dimensional nonwoven materials and methods of manufacturing such materials are disclosed. In one embodiment, a nonwoven material may comprise a plurality of fibers and may further comprise an opposing first surface and a second surface, an apertured zone comprising a plurality of nodes extending away from a base plane on the first surface, a plurality of connecting ligaments interconnecting the plurality of nodes, and a plurality of openings providing a percent open area for the apertured zone that is greater than about 15%, as determined by the Material Sample Analysis Test Method. The material may further comprise a first and second side zones with the nonwoven material having a material width and the first and second side zones having first and second side zone widths, and wherein each of the first and second side zone widths are between about 5% and about 25% of the nonwoven material width.

TECHNICAL FIELD

The present disclosure relates to nonwoven materials. More specifically,the present disclosure relates to three dimensional nonwoven materials.

BACKGROUND OF THE DISCLOSURE

Fibrous nonwoven web materials are in wide use in a number ofapplications including but not limited to absorbent structures andwiping products, many of which are disposable. In particular, suchmaterials are commonly used in personal care absorbent articles such asdiapers, diaper pants, training pants, feminine hygiene products, adultincontinence products, bandages, and wiping products such as baby andadult wet wipes. They are also commonly used in cleaning products suchas wet and dry disposable wipes which may be treated with cleaning andother compounds which are designed to be used by hand or in conjunctionwith cleaning devices such as mops. Yet a further application is withbeauty aids such as cleansing and make-up removal pads and wipes.

In many of these applications, three-dimensionality and increasedsurface area are desirable attributes. This is particularly true withmaterials for the aforementioned personal care absorbent articles andcleaning products. For example, one of the main functions of personalcare absorbent articles is to absorb and retain body exudates such asblood, menses, urine, and bowel movements. Some body exudates, such assolid and semi-solid fecal material and menses, have difficultypenetrating such components of the absorbent article as easily as lowviscosity exudates, such as urine, and tend to spread across the surfaceof such materials. The spread of body exudates across a nonwovenmaterial can result in leakage of the body exudates from the absorbentarticle in which the material is used. Semi-solid fecal material, suchas low viscosity fecal material which can be prevalent with youngerchildren, and menses can be especially difficult to contain in anabsorbent article. These exudates can move around on a body facingmaterial of an absorbent article under the influence of gravity, motion,and pressure by the wearer of the absorbent article. The migration ofthe exudates is often towards the perimeter of the absorbent article,increasing the likelihood of leakage and smears against the skin of thewearer which can make clean-up of the skin difficult and can lead to anincreased potential for skin irritation of a wearer of the absorbentarticle.

While attempts have been made in the past to provide nonwoven materialsthat seek to reduce spreading of body exudates through the creation ofthree-dimensional topography, opportunities for improvement still exist.For example, various types of embossing have been utilized to createthree-dimensionality. However, this approach requires high basis weightmaterials to create a structure with significant topography and theprocess can reduce the thickness of the material due to the inherentnature of the crushing and bonding process of embossing. The densifiedsections from embossing can also create weld points that are imperviousto the passage of body exudates and can cause the material to stiffenand become harsh to the touch.

Other approaches to provide three-dimensionality to nonwoven materialscan include fiber forming on a three-dimensional forming surface andaperturing fibrous webs. Current technologies involving fiber formingcan result in nonwoven materials having low resilience at lower basisweights (assuming soft fibers with desirable aesthetic attributes areused) and the topography is significantly degraded when wound on a rolland put through subsequent converting processes. Aperturing can seek togenerate three-dimensionality by displacing the fiber out of the planeof the original two-dimensional web. Typically, the extent of thethree-dimensionality is limited and, under sufficient load, thedisplaced fiber may be pushed back toward its original positionresulting in at least partial closure of the aperture. Aperturingprocesses that attempt to “set” the displaced fiber outside the plane ofthe original web are also prone to degrading the softness of thestarting web.

As a result, there is a still a need for both a material and a processand apparatus which provide three-dimensional characteristics that meetthe aforementioned needs. There remains a need for a nonwoven materialthat can adequately reduce the spreading of body exudates in theabsorbent article to help reduce the likelihood of leakage of exudatesfrom the absorbent article. There remains a need for a nonwoven materialthat can minimize the amount of body exudates in contact with thewearer's skin. There remains a need for an absorbent article that canprovide physical and emotional comfort to the wearer of the absorbentarticle.

SUMMARY OF THE DISCLOSURE

In one embodiment, a nonwoven material may comprise a plurality offibers and may extend between a first end and a second end, the nonwovenmaterial having a material width and may further comprise a firstsurface and a second surface, the first surface being opposite from thesecond surface, an apertured zone comprising: a plurality of nodesextending away from a base plane on the first surface, a plurality ofconnecting ligaments interconnecting the plurality of nodes, wherein amajority of the plurality of nodes include at least three connectingligaments connecting to adjacent nodes, and a plurality of openingsproviding a percent open area for the apertured zone of the nonwovenmaterial that is greater than about 15%, as determined by the MaterialSample Analysis Test Method; a first side zone and a second side zone,the first side zone having a first side zone width and the second sidezone having a second side zone width, and wherein each of the first sidezone width and the second side zone width may be between about 5% andabout 25% of the nonwoven material width.

In another embodiment, a nonwoven material may comprise a plurality offibers and may extend between a first end and a second end and mayfurther comprise an apertured zone, the apertured zone comprising aplurality of openings providing a percent open area for the aperturedzone of the nonwoven material that is greater than about 15%, asdetermined by the Material Sample Analysis Test Method; and a first sidezone and a second side zone, each of the first side zone and the secondside zone having a percent open area greater than about 0.5% and lessthan the percent open area of the apertured zone, as determined by theMaterial Sample Analysis Test Method, wherein a ratio of a tensilestrength of the first side zone plus a tensile strength of the secondside zone divided by a tensile strength of the apertured zone may bebetween about 0.8 and about 2.5.

In yet another embodiment, another nonwoven material may comprise aplurality of fibers and may extend between a first end and a second endand may further comprise an apertured zone, the apertured zonecomprising a plurality of openings providing a percent open area for theapertured zone of the nonwoven material that is greater than about 15%,as determined by the Material Sample Analysis Test Method, and a firstside zone and a second side zone, each of the first side zone and thesecond side zone having a percent open area greater than about 0.5% andless than the percent open area of the apertured zone, as determined bythe Material Sample Analysis Test Method, wherein a Poisson's ratio ofthe apertured zone of the nonwoven material is less than about 3 at 1%strain, as determined by the Poisson's Ratio Test Method.

BRIEF DESCRIPTION OF DRAWINGS

A full and enabling disclosure thereof, directed to one of ordinaryskill in the art, is set forth more particularly in the remainder of thespecification, which makes reference to the appended figures in which:

FIG. 1 is a top view of an exemplary embodiment of a three-dimensionalnonwoven material according to the present invention.

FIG. 2 is a Scanning Electron Microscope (SEM) image providing adetailed view taken from the embodiment of FIG. 1.

FIG. 3 is an SEM image providing a cross-section view taken from theembodiment of FIG. 1 along line 3-3.

FIG. 4 is a detailed view taken from FIG. 1 illustrating the transmittedlight utilized to calculate the percent open area of the apertured zoneof the nonwoven material of FIG. 1.

FIGS. 5A and 5B are Micro-CT images of cross-sections of two exemplaryembodiments of a nonwoven, taken through a node.

FIG. 5C is a Mirco-CT providing a cross-section of the GentleAbsorb®liner from HUGGIES® Little Snugglers® diapers.

FIG. 5D is a bar graph depicting the results of the testing completedaccording to the Compression Energy Test Method.

FIG. 5E is a bar graph depicting the results of the testing completedaccording to the Compression Linearity Test Method

FIG. 6A is a top view of an alternative embodiment of athree-dimensional nonwoven material.

FIG. 6B is a cross-section view of a portion of the material of FIG. 6Aas viewed along line 6B-6B.

FIG. 6C is a detailed view of a portion of the material of FIG. 6A.

FIG. 6D is an optical image of a portion of the material of FIG. 6A.

FIG. 6E is a detailed view taken from FIG. 6A illustrating thetransmitted light utilized to calculate the percent open area of oneexemplary side zone of the nonwoven material of FIG. 6A.

FIGS. 6F and 6G are top views of alternative embodiments of athree-dimensional nonwoven material.

FIG. 7A is a schematic side view of an exemplary apparatus and processfor manufacturing a three-dimensional nonwoven according to the presentinvention.

FIG. 7B is a schematic side view of an alternative exemplary apparatusand process for manufacturing a three-dimensional nonwoven according tothe present invention.

FIG. 7C is a schematics side view of yet another alternative exemplaryapparatus and process for manufacturing a three-dimensional nonwovenaccording to the present invention.

FIG. 7D is a cross-section of the nonwoven material and carrier materialtaken along line 7D-7D from FIG. 7C.

FIG. 8A is a perspective view of a portion of a forming surface that canbe utilized in the processes of FIGS. 7A-7C.

FIG. 8B is a detailed top view of a portion of an alternative formingsurface that can be utilized in the processes of FIGS. 7A-7C.

FIG. 9 is a perspective side view of an embodiment of an absorbentarticle including a three-dimensional nonwoven material according to thepresent invention.

FIG. 10 is a top plan view of the absorbent article of FIG. 9 withportions cut away for clarity.

FIG. 11A is a cross-section view from FIG. 10 taken along line 11-11.

FIG. 11B is a cross-section view similar to FIG. 11A but of analternative embodiment of an absorbent article.

FIG. 11C is a cross-section view similar to FIGS. 11A and 11B but of yetanother alternative embodiment of an absorbent article.

FIG. 12 is a top plan view of an alternative embodiment of the absorbentarticle of FIG. 9.

FIG. 13 is a top plan view of an exemplary nonwoven material from theabsorbent article of FIG. 12 with an exemplary bonding configurationdepicted with respect to the nonwoven material.

FIG. 14 is a cross-section view from FIG. 12 taken along line 14F-14F.

FIG. 15 is a perspective view of exemplary equipment and set-up toperform the Material Sample Analysis Test Method as described herein.

Repeat use of reference characters in the present specification anddrawings is intended to represent the same or analogous features orelements of the disclosure.

DETAILED DESCRIPTION OF THE DISCLOSURE

In an embodiment, the present disclosure is generally directed towards anonwoven material 10, 110, 210, 310, methods 100′, 100″, 100′″ ofmanufacturing the same, and absorbent articles 410, 510, 610, 710including such exemplary nonwoven materials. Each example is provided byway of explanation and is not meant as a limitation. For example,features illustrated or described as part of one embodiment or figurecan be used on another embodiment or figure to yield yet anotherembodiment. It is intended that the present disclosure include suchmodifications and variations. Any of the discussion below referencing aspecific exemplary nonwoven material 10, 110, 210, 310 is intended toapply to any of the other embodiments of nonwoven material 10, 110, 210,310 described herein unless otherwise stated. Additionally, anydiscussion below referencing a specific method 100′, 100″, 100′″ ofmanufacturing a nonwoven material is intended to apply to any of theother embodiments of methods 100′, 100″, 100′″ of manufacturing anonwoven material described herein unless otherwise stated. Further, anydiscussion below referencing a specific absorbent article 410, 510, 610,710 is intended to apply to any of the other embodiments of theabsorbent articles 410, 510, 610, 710 described herein unless otherwisestated.

When introducing elements of the present disclosure or the preferredembodiment(s) thereof, the articles “a”, “an”, “the” and “said” areintended to mean that there are one or more of the elements. The terms“comprising”, “including” and “having” are intended to be inclusive andmean that there may be additional elements other than the listedelements. Many modifications and variations of the present disclosurecan be made without departing from the spirit and scope thereof.Therefore, the exemplary embodiments described above should not be usedto limit the scope of the invention.

Definitions

The term “absorbent article” refers herein to an article which may beplaced against or in proximity to the body (i.e., contiguous with thebody) of the wearer to absorb and contain various liquid, solid, andsemi-solid exudates discharged from the body. Such absorbent articles,as described herein, are intended to be discarded after a limited periodof use instead of being laundered or otherwise restored for reuse. It isto be understood that the present disclosure is applicable to variousdisposable absorbent articles, including, but not limited to, diapers,diaper pants, training pants, youth pants, swim pants, feminine hygieneproducts, including, but not limited to, menstrual pads or pants,incontinence products, medical garments, surgical pads and bandages,other personal care or health care garments, and the like withoutdeparting from the scope of the present disclosure.

The term “acquisition layer” refers herein to a layer capable ofaccepting and temporarily holding liquid body exudates to decelerate anddiffuse a surge or gush of the liquid body exudates and to subsequentlyrelease the liquid body exudates therefrom into another layer or layersof the absorbent article.

The term “bonded” or “coupled” refers herein to the joining, adhering,connecting, attaching, or the like, of two elements. Two elements willbe considered bonded or coupled together when they are joined, adhered,connected, attached, or the like, directly to one another or indirectlyto one another, such as when each is directly bonded to intermediateelements. The bonding or coupling of one element to another can occurvia continuous or intermittent bonds.

The term “carded web” refers herein to a web containing natural orsynthetic staple length fibers typically having fiber lengths less thanabout 100 mm. Bales of staple fibers can undergo an opening process toseparate the fibers which are then sent to a carding process whichseparates and combs the fibers to align them in the machine directionafter which the fibers are deposited onto a moving wire for furtherprocessing. Such webs are usually subjected to some type of bondingprocess such as thermal bonding using heat and/or pressure. In additionto or in lieu thereof, the fibers may be subject to adhesive processesto bind the fibers together such as by the use of powder adhesives. Thecarded web may be subjected to fluid entangling, such ashydroentangling, to further intertwine the fibers and thereby improvethe integrity of the carded web. Carded webs, due to the fiber alignmentin the machine direction, once bonded, will typically have more machinedirection strength than cross machine direction strength.

The term “film” refers herein to a thermoplastic film made using anextrusion and/or forming process, such as a cast film or blown filmextrusion process. The term includes apertured films, slit films, andother porous films which constitute liquid transfer films, as well asfilms which do not transfer fluids, such as, but not limited to, barrierfilms, filled films, breathable films, and oriented films.

The term “fluid entangling” and “fluid-entangled” generally refersherein to a formation process for further increasing the degree of fiberentanglement within a given fibrous nonwoven web or between fibrousnonwoven webs and other materials so as to make the separation of theindividual fibers and/or the layers more difficult as a result of theentanglement. Generally this is accomplished by supporting the fibrousnonwoven web on some type of forming or carrier surface which has atleast some degree of permeability to the impinging pressurized fluid. Apressurized fluid stream (usually multiple streams) is then directedagainst the surface of the nonwoven web which is opposite the supportedsurface of the web. The pressurized fluid contacts the fibers and forcesportions of the fibers in the direction of the fluid flow thusdisplacing all or a portion of a plurality of the fibers towards thesupported surface of the web. The result is a further entanglement ofthe fibers in what can be termed the Z-direction of the web (itsthickness) relative to its more planar dimension, its X-Y plane. Whentwo or more separate webs or other layers are placed adjacent oneanother on the forming/carrier surface and subjected to the pressurizedfluid, the generally desired result is that some of the fibers of atleast one of the webs are forced into the adjacent web or layer therebycausing fiber entanglement between the interfaces of the two surfaces soas to result in the bonding or joining of the webs/layers together dueto the increased entanglement of the fibers. The degree of bonding orentanglement will depend on a number of factors including, but notlimited to, the types of fibers being used, their fiber lengths, thedegree of pre-bonding or entanglement of the web or webs prior tosubjection to the fluid entangling process, the type of fluid being used(liquids, such as water, steam or gases, such as air), the pressure ofthe fluid, the number of fluid streams, the speed of the process, thedwell time of the fluid and the porosity of the web or webs/other layersand the forming/carrier surface. One of the most common fluid entanglingprocesses is referred to as hydroentangling which is a well-knownprocess to those of ordinary skill in the art of nonwoven webs. Examplesof fluid entangling process can be found in U.S. Pat. No. 4,939,016 toRadwanski et al., U.S. Pat. No. 3,485,706 to Evans, and U.S. Pat. Nos.4,970,104 and 4,959,531 to Radwanski, each of which is incorporatedherein in its entirety by reference thereto for all purposes.

The term “gsm” refers herein to grams per square meter.

The term “hydrophilic” refers herein to fibers or the surfaces of fiberswhich are wetted by aqueous liquids in contact with the fibers. Thedegree of wetting of the materials can, in turn, be described in termsof the contact angles and the surface tensions of the liquids andmaterials involved. Equipment and techniques suitable for measuring thewettability of particular fiber materials or blends of fiber materialscan be provided by Cahn SFA-222 Surface Force Analyzer System, or asubstantially equivalent system. When measured with this system, fibershaving contact angles less than 90 are designated “wettable” orhydrophilic, and fibers having contact angles greater than 90 aredesignated “nonwettable” or hydrophobic.

The term “liquid impermeable” refers herein to a layer or multi-layerlaminate in which liquid body exudates, such as urine, will not passthrough the layer or laminate, under ordinary use conditions, in adirection generally perpendicular to the plane of the layer or laminateat the point of liquid contact.

The term “liquid permeable” refers herein to any material that is notliquid impermeable.

The term “meltblown” refers herein to fibers formed by extruding amolten thermoplastic material through a plurality of fine, usuallycircular, die capillaries as molten threads or filaments into converginghigh velocity heated gas (e.g., air) streams which attenuate thefilaments of molten thermoplastic material to reduce their diameter,which can be a microfiber diameter. Thereafter, the meltblown fibers arecarried by the high velocity gas stream and are deposited on acollecting surface to form a web of randomly dispersed meltblown fibers.Such a process is disclosed, for example, in U.S. Pat. No. 3,849,241 toButin et al., which is incorporated herein by reference. Meltblownfibers are microfibers which may be continuous or discontinuous, aregenerally smaller than about 0.6 denier, and may be tacky andself-bonding when deposited onto a collecting surface.

The term “nonwoven” refers herein to materials and webs of materialwhich are formed without the aid of a textile weaving or knittingprocess. The materials and webs of materials can have a structure ofindividual fibers, filaments, or threads (collectively referred to as“fibers”) which can be interlaid, but not in an identifiable manner asin a knitted fabric. Nonwoven materials or webs can be formed from manyprocesses such as, but not limited to, meltblowing processes,spunbonding processes, carded web processes, etc.

The term “pliable” refers herein to materials which are compliant andwhich will readily conform to the general shape and contours of thewearer's body.

The term “spunbond” refers herein to small diameter fibers which areformed by extruding molten thermoplastic material as filaments from aplurality of fine capillaries of a spinnerette having a circular orother configuration, with the diameter of the extruded filaments thenbeing rapidly reduced by a conventional process such as, for example,eductive drawing, and processes that are described in U.S. Pat. No.4,340,563 to Appel et al., U.S. Pat. No. 3,692,618 to Dorschner et al.,U.S. Pat. No. 3,802,817 to Matsuki et al., U.S. Pat. Nos. 3,338,992 and3,341,394 to Kinney, U.S. Pat. No. 3,502,763 to Hartmann, U.S. Pat. No.3,502,538 to Peterson, and U.S. Pat. No. 3,542,615 to Dobo et al., eachof which is incorporated herein in its entirety by reference. Spunbondfibers are generally continuous and often have average deniers largerthan about 0.3, and in an embodiment, between about 0.6, 5 and 10 andabout 15, 20 and 40. Spunbond fibers are generally not tacky when theyare deposited on a collecting surface.

The term “superabsorbent” refers herein to a water-swellable,water-insoluble organic or inorganic material capable, under the mostfavorable conditions, of absorbing at least about 15 times its weightand, in an embodiment, at least about 30 times its weight, in an aqueoussolution containing 0.9 weight percent sodium chloride. Thesuperabsorbent materials can be natural, synthetic and modified naturalpolymers and materials. In addition, the superabsorbent materials can beinorganic materials, such as silica gels, or organic compounds, such ascross-linked polymers.

The term “thermoplastic” refers herein to a material which softens andwhich can be shaped when exposed to heat and which substantially returnsto a non-softened condition when cooled.

The term “user” or “caregiver” refers herein to one who fits anabsorbent article, such as, but not limited to, a diaper, diaper pant,training pant, youth pant, incontinent product, or other absorbentarticle about the wearer of one of these absorbent articles. A user anda wearer can be one and the same person.

Three-dimensional Web with Nodes, Ligaments, and Openings:

As depicted in FIGS. 1-3, a three-dimensional nonwoven material 10 caninclude a plurality of nodes 12 and a plurality of connecting ligaments14 (only one of the nodes 12 and one of the connecting ligaments 14being labeled in FIG. 1 for clarity purposes). The nodes 12 andconnecting ligaments 14 can be disposed within an apertured zone 16 ofthe material 10. As best illustrated in the cross-sectional view of FIG.3, the nodes 12 can extend away from a base plane 18 on a first surface20 of the nonwoven material 10. The base plane 18 can be defined as thegenerally planar region of the first surface 20 of the nonwoven material10 other than the portion of the nonwoven material 10 forming the nodes12. In other words, for the embodiment depicted in FIGS. 1-3, the baseplane 18 can be formed by the first surface 20 of the nonwoven material10 that provides the connecting ligaments 14. The nonwoven material 10can also include a second surface 22. The first surface 20 can beopposite from the second surface 22, as depicted in FIG. 3.

The nodes 12 can be configured in a variety of shapes and sizes as willbe discussed in further detail below in the discussion of themanufacturing of the nonwoven material 10. In some embodiments, thenodes 12 can be generally cylindrical in shape. In preferredembodiments, the nodes 12 are configured to not include any openings orapertures. In some embodiments, the nodes 12 can have a height 15 (asmeasured in a direction perpendicular to the base plane 18) of betweenabout 1 mm to about 10 mm, and more preferably, from about 3 mm to about6 mm. The height 15 of the nodes 12 is measured using the analysistechniques described in the Node Analysis Test Method described in theTest Methods section herein. In some embodiments, a majority of thenodes 12 can each have an area (as measured by the area of the node 12within the base plane 18) of about 5 mm² to about 35 mm², and morepreferably, from about 10 mm² to about 20 mm². The plurality of nodes 12can be configured in the apertured zone 16 such that the nodes 12provide a node density of about 1.0 nodes/cm² to about 3.0 nodes/cm².The node area and node density within the apertured zone 16 can bemeasured using the analysis techniques described in the Material SampleAnalysis Test Method described in the Test Methods section herein.

As depicted in FIG. 1 and in more detail in FIG. 2, the connectingligaments 14 can interconnect the plurality of nodes 12. An individualconnecting ligament 14 can be referred to as extending between only twoadjacent nodes 12. In other words, an individual connecting ligament 14does not interconnect three or more nodes 12. In preferred embodiments,a majority of the plurality of nodes 12 can include at least threeconnecting ligaments 14 connecting to adjacent nodes 12. In preferredembodiments, a majority of the plurality of nodes 12 can include ten orless connecting ligaments 14 connecting to adjacent nodes 12. In someembodiments, the nonwoven material 10 can be configured such that amajority of the plurality of nodes 12 can include three to eightconnecting ligaments 14 connecting to adjacent nodes 12. For example, inthe embodiment depicted in FIGS. 1 and 2, a majority of the plurality ofnodes 12 include six connecting ligaments 14 that connect to adjacentnodes 12. In other embodiments, it can be preferable to have a majorityof the plurality of nodes 12 include three to six connecting ligaments14 connecting to adjacent nodes 12, and in some embodiments, preferablyinclude three to four connecting ligaments 14 connecting to adjacentnodes 12.

The nonwoven material 10 can also include a plurality of openings 24 inthe apertured zone 16. The openings 24 can also be referred to herein as“apertures”. The openings 24 as described herein are areas of thenonwoven material 10 that have a lower density of fibers of the nonwovenmaterial 10 in comparison to nodes 12 and connecting ligaments 14. Insome embodiments, the openings 24 can be substantially devoid of fibers.As used herein, the openings 24 are to be distinguished from the normalinterstitial fiber-to-fiber spacing commonly found in fibrous nonwovenmaterials. For example, FIG. 2 provides an SEM image of an exemplarynonwoven material 10 labels one opening 24 which includes a lowerdensity of fibers than adjacent nodes 12 and connecting ligaments 14.The openings 24 can be formed between the plurality of connectingligaments 14 and the plurality of nodes 12. Individual openings 24 canbe disposed between adjacent nodes 12. Individual openings 24 can bedefined between at least three connecting ligaments 14 and at leastthree nodes 12. In some embodiments, individual openings 24 can bedefined between at least four connecting ligaments 14 and at least fournodes 12. In some embodiments, a majority of the plurality of openings24 can be configured such that each has an area (as measured by the areaof the opening 24 within the base plane 18) that ranges from about 5 mm²to about 25 mm², more preferably from about 7 mm² to about 20 mm², andeven more preferably, from about 7 mm² to about 17 mm². The area of theopenings 24 within the apertured zone 16 can be measured using theanalysis techniques in the Material Sample Analysis Test Method asdescribed in the Test Methods section herein.

In some embodiments, the plurality of openings 24 for the nonwovenmaterial 10 can provide a percent open area for the apertured zone 16from about 10% to about 60%. In some preferred embodiments, theplurality of openings 24 for the nonwoven material 10 can provide apercent open area for the apertured zone 16 from about 15% to about 45%.In some preferred embodiments, the nonwoven material 10 can provide apercent open area for the apertured zone 16 from about 20% to about 40%,or even more preferably from about 20% to about 30%. As used herein, thepercent open area is determined using the Material Sample Analysis TestMethod as described in the Test Methods section herein. Although it isdescribed in detail in the Test Methods section, the Material SampleAnalysis Test Method involves projecting a light source on the nonwovenmaterial 10 such that the openings 24 can be identified by the propertythat the openings 24 allow a greater percentage of light to pass throughthe nonwoven material 10, which is illustrated in FIG. 4 (with onlythree openings 24 being labeled for purposes of clarity), as compared tonodes 12 and ligaments 14.

The plurality of openings 24 can provide a variety of beneficialproperties to the nonwoven material 10. For example, the openings 24 canprovide enhanced fluid transfer for the nonwoven material 10 and/orincreased permeability. As an example, if the nonwoven material 10 isutilized in an article that intakes and distributes fluid, the openings24 can help provide increased intake and distribution of fluids throughand/or across the nonwoven material 10.

In particular, the plurality of openings 24 can enhance the ability of amaterial like the nonwoven material 10 to intake and distribute BMmaterial (also referred to herein as feces or fecal matter), resultingin less pooling of the BM on the material 10 and therefore less BMdisposed against a skin of a wearer of an absorbent article comprisingsuch nonwoven material 10. In order to determine the ability ofdifferent nonwoven materials to effectively handle simulated BM, anumber of different nonwoven materials 10 (Materials A-F), according toaspects of the present disclosure, were tested utilizing a test methodwhich determined a BM pooled percent value. Such a test method isdescribed as a “Determination of Residual Fecal Material Simulant” testmethod in U.S. Pat. No. 9,480,609, titled “Absorbent Article”, theentirety of which is hereby incorporated by reference to the extent notcontradictory herewith. The different nonwoven materials tested were allformed in a similar manner but with different forming surfaces resultingin different patterns of nodes 12, ligaments 14, and openings 24. Thesedifferent patterns produced differences in percent open area valueswithin the apertured zone 16, average opening areas, and material bulkproperties of the formed nonwoven materials. The different nonwovenmaterials, and their properties and performance results, are shown belowin Table 1.

TABLE 1 BM Open Average Material Pooled Area Bulk Opening Area Code (%)(%) (mm) (mm²) A 35.87 21.91 2.301 10.52 B 26.60 27.31 2.876 11.81 C21.35 28.32 2.935 15.74 D 23.31 30.75 3.746 20.13 E 24.58 22.32 3.96113.79 F 23.62 28.94 4.02 19.73 GentleAbsorb ® 42.57 0 1.5 0

Primarily, it can be seen how effective materials which have openings24, providing such materials with percent open area values in theaperture zone 16, are in terms of reducing the amount of pooled BM onsuch materials. For example, as shown in Table 1, Material A, having thelowest percent open area value, still performed significantly betterthan the GentleAbsorb® material in terms of an amount of BM left pooled.In fact, all of the tested Materials A-F performed well in comparison tothe performance of the GentleAbsorb® material, generally supporting apreferred percent open area range of at least about 20%, or at leastabout 25%, or at least about 30%, or between about 20% and about 30%.

It can also be seen that it may be preferred, along with such nonwovenmaterials 10 having the minimum percent open area values of theapertured zone 16 described herein, or percent open area value rangesdescribed herein, it may be preferred for the nonwoven materials 10 tohave openings 24 which have relatively larger average area. For example,it can be seen from Table 1 that Materials A and E have similar percentopen area values. However, Material E performed significantly betterthan Material A with respect to the BM left pooled. As seen in Table 1,Material E has an average opening area of 13.79 mm² while the Material Aonly has an average opening area of 10.52 mm². Accordingly, it may bepreferred to the nonwoven materials 10 of the present disclosure to haveaverage open areas of at least 10.52 mm², or at least about 11 mm², orat least about 12 mm², or at least about 13 mm², or at least 13.79 mm².It may be beneficial for the nonwoven materials of the presentdisclosure to have such average areas of the openings 24 while having apercent open area value of the nonwoven material in the apertured zone16 of at least 21.91%, or at least about 22%, or at least about 23%, orbetween about 20% and about 30%.

In some particularly preferred embodiments of the nonwoven materials ofthe present disclosure, it may be preferable for such materials to havea percent open area value of greater than about 27%, or greater thanabout 27.31% and less than about 31%, or less than about 30.75%. Forexample, Materials B, C, and D show Material C performing the betterthan both Materials B and C, with Materials B and D having percent openarea values less than and greater than Material C, respectively.Alternatively, it may be preferable for embodiments of the nonwovenmaterials of the present disclosure to have average areas of openings 24that are greater than about 11.81 mm², or greater than about 12 mm² andless than about 20.13 mm², or less than about 21 mm². For instance,Materials B, C, and D show Material C performing better than bothMaterials B and D, with Materials B and D having average area values ofthe openings 24 less than and greater than Material C, respectively. Instill further embodiments, it may be preferred for the nonwovenmaterials of the present disclosure to have a percent open area value ofgreater than about 27%, or greater than about 27.31% and less than about31%, or less than about 30.75% and also have average opening areas ofgreater than about 11.81 mm², or greater than about 12 mm² and less thanabout 20.13 mm², or less than about 21 mm².

FIGS. 5A-5C provide examples of another beneficial property of thenonwoven material 10 related to fiber orientation. In preferredembodiments of the nonwoven material 10, such as shown in thecross-sections of FIGS. 5A and 5B, at least a majority of the pluralityof nodes 12 can be configured such that they have an anisotropy valuegreater than 1.0 as measured by the Node Analysis Test Method, describedin the Test Methods section herein. The nodes 12 have a higher level offiber alignment in a direction 32 perpendicular to the base plane 18 onthe first surface of the nonwoven material 10. FIG. 5C provides acomparative example of a nonwoven material currently used and marketedas a GentleAbsorb® liner in HUGGIES® Little Snugglers® diapersmanufactured and sold by Kimberly-Clark Global Sales, LLC, which isdescribed in U.S. Pat. No. 9,327,473. The anisotropy values for thenonwoven materials of FIGS. 5A-5C are shown in Table 2 below. As shownin Table 2, the nonwoven materials 10 from FIGS. 5A and 5B included ananisotropy value greater than 1.0, having anisotropy values of 1.07 and1.25, respectively.

TABLE 2 Anisotropy Values for Samples from FIGS. 5A-5C AnisotropyStandard Sample Value Deviation Nonwoven from FIG. 5A 1.07 0.04 Nonwovenfrom FIG. 5B 1.25 0.09 GentleAbsorb ® Liner (FIG. 5C) 0.94 0.03

Not to be bound by theory, but it is believed that the improvedanisotropy values in the nodes 12 of the nonwoven material 10 describedherein can be created by increasing the aspect ratio of the depth of theforming holes 54 compared to the diameter of the forming holes 54, aswill be discussed in greater detail below.

Additionally, it is believed that the increased anisotropy values of thenonwoven materials 10 according to this description provide improvedcompression resistance for the nonwoven material 10 as compared to othernonwoven materials, including as compared to the GentleAbsorb® Linermaterial. With improved compression resistance, the nonwoven material 10can maintain its loft through application and use in a variety ofenvironment where it may be exposed to compressive forces. For example,when used in an absorbent article, the nonwoven material 10 can be undercompressive forces from its initial packaging state of being incompressed packaging to application on the wearer if the wearer is in asitting or lying position on the absorbent article. By providingimproved resistance to compression, the nonwoven material 10 can helpmaintain void volume for accepting, transferring, and/or storing bodyexudates from a wearer. In doing so, the nonwoven material 10 canprovide enhanced skin benefits for the wearer by helping keep bodyexudates away from a wearer's skin and potential product improvements bykeeping body exudates away from the edges of the absorbent article,which may be a source of leaks.

As depicted in FIGS. 5D and 5E, an exemplary nonwoven material 110described herein (depicted in FIG. 6A) was tested in twocompression-related test methods against a comparative example of anonwoven material currently used and marketed as a GentleAbsorb® linerin HUGGIES® Little Snugglers® diapers manufactured and sold byKimberly-Clark Global Sales, LLC, which is described in U.S. Pat. No.9,327,473. A Micro-CT cross-sectional image of a sample of theGentleAbsorb® liner material is depicted in FIG. 5C. FIG. 5D shows theresults of the Compression Energy Test and FIG. 5E shows the results ofthe Compression Linearity Test. The results of this testing will now bediscussed.

The Compression Energy Test is described more fully in the Test Methodssection herein, but measures the compression resiliency of a materialthrough three cycles of compression by measuring the energy required tocompress the nonwoven material from its initial thickness at 5 gramsforce down to its final thickness at about 1830 grams force (about 10kPa). As depicted in FIG. 5D, the nonwoven material 110 of the presentdisclosure required higher amounts of compression energy in each cycleto compress than compared to the compression energy required to compressthe control code of the GentleAbsorb® liner, and thus, provides greatercompression resilience. In fact, the results of the Compression EnergyTesting show that the nonwoven material 110 provide benefits over thecontrol code In particular, the nonwoven material 110 provided acompression energy greater than 40 gf*cm in cycle 1 and greater than 35gf*cm in cycles 2 and 3. In fact, the nonwoven material provided acompression energy greater than 50 gf*cm in cycles 2 and 3, and greaterthan 60 gf*cm in cycle 1.

Thus, it is preferable if the nonwoven materials of the presentdisclosure provide a compression energy greater than 40 gf*cm, morepreferably greater than 45 gf*cm, more preferably greater than 50 gf*cm,even more preferably greater than 55 gf*cm, and still even morepreferably greater than 60 gf*cm in cycle 1 of the Compression EnergyTest. It is preferable if the nonwoven materials of the presentdisclosure provide a compression energy between 40-65 gf*cm in cycle 1of the Compression Energy Test. It is also preferable if the nonwovenmaterials of the present disclosure provide a compression energy greaterthan 35 gf*cm, more preferably greater than 40 gf*cm, more preferablygreater than 45 gf*cm, and even more preferably greater than 50 gf*cm incycle 2 of the Compression Energy Test. Therefore, it is preferable ifthe nonwoven materials of the present disclosure provide a compressionenergy between 40-55 gf*cm in cycle 2 of the Compression Energy Test. Itis also preferable if the nonwoven materials of the present disclosureprovide a compression energy greater than 35 gf*cm, more preferablygreater than 40 gf*cm, more preferably greater than 45 gf*cm, and evenmore preferably greater than 50 gf*cm in cycle 3 of the CompressionEnergy Test. It is preferable if the nonwoven materials of the presentdisclosure provide a compression energy between 40-55 gf*cm in cycle 3of the Compression Energy Test.

By providing more compression resilience, the nonwoven materials of thepresent disclosure can provide additional benefits. For example, whenthe nonwoven material 10 is used in an absorbent article 410, thenonwoven material 10 can maintain void volume for handling bodyexudates, intaking them into the absorbent assembly 444, which can helpkeep the skin of the user drier and more comfortable. This benefit mayparticularly be realized in embodiments in which the nonwoven material10 is configured in the absorbent article 410 such that nodes 12 extendfrom the base plane 18 of the first surface 20 of the nonwoven material10 toward the absorbent body 434. Additionally, by being morecompression resilient, the nonwoven material 10 can potentially providemore loft and a softer feel to the skin of a wearer wearing such anabsorbent article 410.

FIG. 5E depicts the results of the Compression Linearity Test. TheCompression Linearity Test, as described fully in the Test Methodssection herein, is designed to measure the compression properties of thenonwoven material by compressing the material at a constant rate betweentwo plungers until it reaches a maximum preset force. The displacementof the top plunger compressing the material is detected by apotentiometer. The amount of pressure taken to compress the sample (P,gf/cm²) vs. thickness (displacement) of the material (T, mm) is plottedon the computer screen. The value of compression linearity representsthe degree of linearity of the compression curve. The higher thecompression linearity value, the more resistant a material is to beingcompressed. As illustrated in FIG. 5E, the nonwoven material 110exhibited a compression linearity of about 0.75 whereas the control codeof the GentleAbsorb® liner exhibited a compression linearity of lessthan 0.50. Thus, in preferred embodiments, the nonwoven materialspreferably have a compression linearity of greater than 0.50, morepreferably greater than 0.55, more preferably greater than 0.60, evenmore preferably greater than 0.65, and most preferably greater than0.70. In some embodiments, the nonwoven material can have a compressionlinearity of between about 0.50 and 1.0, or between about 0.50 and about0.80.

In some embodiments, the nonwoven material 10 can include side zonesand/or end zones which are different than the apertured zone 16. Forexample, as shown in FIG. 1, the nonwoven material 10 can include afirst side zone 26 a and a second side zone 26 b. The first and secondside zones 26 a and 26 b can be generally parallel to one another andextend in a longitudinal direction 28. The first and second side zones26 a and 26 b can be configured such that the first side zone 26 a isadjacent to a first side 16 a of the apertured zone 16 and the secondside zone 26 b is adjacent to a second side 16 b of the apertured zone16. Put another way, the apertured zone 16 may be disposed between thefirst side zone 26 a and the second side zone 26 b. In at least someembodiments, the side zones 26 a, 26 b can extend from the front edge 25of the material 10 all the way to the back edge 27 of the material 10.Additionally, in some embodiments the apertured zone 16 may extend fromthe front edge 25 of the material 10 all the way to the back edge 27 ofthe material 10, such that the material 10 does not have any end zones26 c, 26 d. Although, in other embodiments the side zones 26 a and/or 26b can extend only partially along the length of the nonwoven material10. In such embodiments, the apertured zone 16 may extend fully betweenlateral side edges 47, 49 of the nonwoven material 10 along at least aportion of a length of the material 10.

The nonwoven material 10 can have a width 35 defined between the lateralside edges 47, 49. The side zones 26 a, 26 b have widths 31 a, 31 b,respectively, while the apertured zone 16 has a width 33. Although shownas constant in FIG. 1, the widths 31 a, 31 b may vary in otherembodiments. For instance, the material 10 could be formed with anapertured zone 16 whose edges curve and/or undulate in the longitudinaldirection 28. In such embodiments, the widths 31 a, 31 b may increaseand/or decrease correspondingly to the shape of the apertured zone 16.As used herein, the widths 31 a, 31 b may refer to the greatest widththat the side zones 26 a, 26 b achieve along the length of the material10.

In general, it may be beneficial for the side zones 26 a, 26 b to havewidths 31 a, 31 b which are not too great of a percentage of an overallwidth 35 of the material 10. For instance, the side zones 26 a, 26 b maygenerally have a greater tensile strength than the apertured zone 16.Accordingly, one benefit of the side zones 26 a, 26 b is that they canhelp to provide the material 10 with a greater overall tensile strengthand thus help the material 10 to be processable within high-speedmanufacturing processes where the material 10 is processed under tension(for example, high-speed absorbent article manufacturing processes).However, if the widths 31 a, 31 b of the side zones 26 a, 26 b are toogreat it has been found that the material 10 will curl undesirably whenput under tension such that the material 10 may not be processable indesired high-speed manufacturing processes. For example, this curlingcan cause edges of the nonwoven materials to undesirably fold as thematerials traverse along a web path within a manufacturing process. Itis believed that the difference in tensile strength between the sidezones 26 a, 26 b and the apertured zone 16 is a key contributing factorto this curling.

In order to help prevent material 10 from curling, or at least curlingto such a degree as to impact the processability of the material 10within a high-speed manufacturing process, it has been found that it isdesirable to keep the widths 31 a, 31 b under certain percentage valuesof the overall width of the material 10. It is believed that such afeature helps to ensure that the higher tensile strengths of the sidezones 26 a, 26 b do not dominate the performance of the material 10 whensubjected to the tensions of high-speed manufacturing processes. It hasbeen found that material 10, and the other materials of the presentdisclosure, maintain desirable curling properties when subjected to thetensions in typical high-speed manufacturing processes if the widths 31a, 31 b are each less than about 20% of the overall width 35 of thematerial 10. It may be more preferable if the widths 31 a, 31 b are eachless than about 25%, or less than about 20%, or less than about 17.5%,or less than about 15%, less than about 12.5% or less than about 10% ofthe overall width 35 of the material 10. In at least some of theseembodiments, the widths 31 a, 31 b may each be greater than about 5% ofthe overall width 35 of the material 10. Consequently, the aperturedzone width 33 may be between about 50% and about 90%, or between about60% and about 90%, or between about 65% and about 90%, or between about70% and about 90%, or between about 75% and about 90%, or between about80% and about 90% of the overall width 35 of the material 10.

The widths 31 a, 31 b may each have similar values. For instance, thewidths 31 a, 31 b may have values such that one of widths 31 a, 31 b iswithin about 50% of the value of the other of the widths 31 a, 31 b, orwithin about 25% of the value of the other of the widths 31 a, 31 b.

In embodiments where the material 10 is used within an absorbentarticle, the side zones 26 a, 26 b may be used to adhere the material 10to an absorbent article chassis. In these embodiments, the widths 31 a,31 b can be configured to provide a sufficient area to bond the material10 to the article chassis and to ensure that the material 10 is bondedwith sufficient strength such that the material 10 does not delaminateduring manufacture or in-use. It has been found that widths 31 a, 31 bwhich provide such benefits are between about 10 mm to about 40 mm, orbetween about 10 mm and about 35 mm, or between about 10 mm and about 30mm, or between about 10 mm and about 25 mm, or between about 10 mm andabout 20 mm.

It has further been found that it in order to manage curling of thematerial 10 under tension, such as tensions the material 10 may be putunder within high-speed manufacturing processes, there is a TensileStrength Ratio that may be targeted to achieve between the zones 16, 26a, 26 b. The Tensile Strength Ratio is described in detail in thediscussion of the Tensile Strength Test Method in the Test Methodssection herein. In general, the Tensile Strength Ratio compares theadditive Tensile Strength of both side zones 26 a, 26 b against theTensile Strength of the apertured zone 16. If a preferable TensileStrength Ratio is achieved, the dimensions of the side zones 26 a, 26 bdo not need to be constrained under a certain percentage of the overallwidth 35 of the material 10 in order to achieve a desired curlingperformance. Speaking generally, it has been found that the more eventhe tensile strength of the material 10 is across its width 35, the lessthe material 10 curls when put under tension. More specifically, it hasbeen found that material 10, and other materials of the presentdisclosure, may perform adequately from a curling standpoint if theirTensile Strength Ratio is greater than about 0.8 and less than about2.5. In other embodiments, the Tensile Strength Ratio may be morepreferred to be between about 0.8 and about 2, or between about 0.8 andabout 1.75, or between about 0.8 and about 1.5. To determine the tensilestrength of the different zones 16, 26 a, 26 b, the material 10 wassubjected to the Tensile Strength Test Method. The Tensile StrengthRatio of the material 10 may then be calculated according to Equation(1) as noted in the Tensile Strength Test Method.

Although the side zones 26 a, 26 b help to provide greater overalltensile strength to the material 10, the side zones 26 a, 26 b of thematerial 10 have not been found to appreciably affect a necking propertyof the material 10. As used herein, necking is used to refer to thetendency for a material's width to decrease as the material is subjectedto increasing longitudinal tension. One material property which is usedas a measure of necking is a material's Poisson's ratio. It has beenfound that the material 10, or more specifically the apertured zone 16of the material 10, may need to have a relatively low Poisson's ratio inorder be processible in a high-speed manufacturing process such as anabsorbent article manufacturing process.

As one illustrative example where the material 10 is used as part of anabsorbent article, if the material 10 necks too much under tension itmay end up not covering a desired width of the absorbent article. Suchextreme necking can cause adhesive within the article to be leftuncovered by the material 10. This exposed adhesive can undesirably bondother features of the absorbent article together or make opening of sucharticles difficult. It has been found that beneficial Poisson's ratiosof the apertured zone 16 of the material 10 which ensure any necking ofthe material 10 is not too great, are those ratios that are less thanabout 3 at 1% strain, or less than about 2.5 at 1% strain, or less thanabout 2 at 1% strain, or less than about 1.5 at 1% strain. The Poisson'sratio of the apertured zone 16 can be found according to the Poisson'sRatio Test Method as described in the Test Methods section herein.

Another feature of the side zones 26 a, 26 b is that they may havepercent open area values lower than such percent open area values forthe apertured zone 16. As described previously, the percent open areavalue of the apertured zone 16 is desired to be sufficiently high tohelp produce desirable intake properties of the material 10. The sidezones 26 a, 26 b, conversely, do not need to perform similarly to theapertured zone 16 with respect to intake or other fluid handlingproperties. Accordingly, in some embodiments the side zones 26 a, 26 bmay have a percent open area value that is less than the percent openarea value of the apertured zone 16. It may be more preferable for theside zones 26 a, 26 b to have percent open area values that are lessthan about 10%, or less than about 8%, or less than about 6%.

It is also the case that the side zones 26 a, 26 b may have minimumpercent open area values. For instance, where the material 10 is a fluidentangled material, the forming process may operate to formmicro-apertures 81 within the side zones 26 a, 26 b. The forming processmay additionally or alternatively form areas of greatly reduced fiberdensity 39, where the process moves fibers from first regions of aforming surface (e.g., portions of the outer surface 58 of the formingsurface 50 between apertures 71 as shown in FIG. 8A) used to form thematerial 10 toward second regions of the forming surface (e.g.,apertures 71 as shown in FIG. 8A). These micro-apertures 81 and regionsof greatly reduced fiber density 39 can both contribute to thedetermined percent open area value of the side zones 26 a, 26 b. Thesefeatures may be seen in FIG. 6E.

Where the material 10 is a fluid entangled material, it has been foundthat the percent open area values of the side zones 26 a, 26 b maygenerally be greater than about 0.5%, or greater than about 0.6%, orgreater than about 0.7% or greater than about 0.8%, or greater thanabout 0.9%, or greater than about 1.0%, or greater than about 1.25%, orgreater than about 2.5%, as determined according to the Material SampleAnalysis Test Method. It has been found that the percent open areavalues of the side zones 26 a, 26 b in the fluid-entangled nonwovenmaterials of the present disclosure, such as material 10, are generallygreater than the percent open area values of conventional nonwovenmaterials of similar basis weights, such as spunbond materials,meltblown materials, and even spunlace materials, which do not haveopenings and/or projections or whereby the openings and/or projectionsare not formed integrally during formation of such materials.

As described above, where the material 10 is a fluid entangled material,the forming process may form regions of decreased fiber density withinthe side zones 26 a, 26 b. Consequently, the formation process may alsoform regions of increased fiber density within the side zones 26 a, 26b, for example, in regions corresponding to apertures 71 in the formingsurface 50. As the fibers migrate toward apertures 71 in the formingsurface 50, the apertures 71 at least partially fill with fibers,thereby forming micro-bumps 13, as shown in FIG. 6B. This formationprocess of the micro-bumps 13 may be generally similar to the process offorming the nodes 12 of the apertured zone 16, although the resultingmicro-bumps 13 may have a height 17 that is considerably less than theheight 15 of the nodes 12. For instance, the micro-bumps 13 may haveheights 17 of between about 0.35 mm and about 1.0 mm, or between about0.4 mm and about 0.9 mm, or between about 0.5 mm and about 0.9 mm, orbetween about 0.5 mm and about 0.8 mm.

Although optional, the nonwoven material 10 can further include a firstend zone 26 c and a second end zone 26 d. The first end zone 26 c andthe second end zone 26 d can be generally parallel to one another andextend in a lateral direction 30. The first end zone 26 c and the secondend zone 26 d can be configured such that the first end zone 26 c isadjacent to a first end 16 c of the apertured zone 16 and the second endzone 26 d is adjacent to a second end 16 d of the apertured zone 16. Anysuch endzones 26 c, 26 d may be similar in any fashion to the side zones26 a, 26 b as described above.

The openings 24 of the apertured zone 16 can be configured in a varietyof shapes and orientations. In the embodiment illustrated in FIGS. 1-4,the openings 24 are each configured to be generally triangular in shape.As best shown in FIGS. 1 and 4, the triangular shape of various openings24 can be in various orientations. As will be described in more detailbelow, the openings 24 can be configured in various other shapes andconfigurations, which can be driven by the process and equipment for howthe nonwoven material 10 is manufactured.

In some particular embodiments, the openings 24 may have a generallyovular shape. For example, as seen in FIGS. 6A, 6C, and 6D, the openings24 are oblong with generally rounded sides. In at least some embodimentsof the present disclosure, the openings 24 may have a major dimension 41and a minor dimension 43, as shown in FIG. 6D. The major dimension 41may be the greatest distance between two points on the material 110surrounding an individual opening 24 while the minor dimension 43 may bethe smallest distance between two points on the material 110 surroundingan individual opening 24 and which passes through a center of theopening 24. The center may be the geometric center. In some embodimentsaccording to the present disclosure, it may be beneficial for the majordimension 41 to be oriented such that it extends substantially in thelongitudinal direction 28. As used herein, the major dimension 41 isoriented to extend substantially in the longitudinal direction 28 whenthe major dimension 41 forms an angle 45 with respect to thelongitudinal direction 28 of less than forty-five degrees. In someparticular embodiments, a majority of the openings 24 may have theirmajor dimension 41 extend substantially in the longitudinal direction28. In further embodiments, all of the openings 24 may have their majordimension 41 extend substantially in the longitudinal direction 28.

Such embodiments where the major dimension 41 of the openings 24 of thematerial 110, and other materials of the present disclosure, extendsubstantially in the longitudinal direction 28 may perform better withrespect to intake than other embodiments when used within an absorbentarticle. As liquid and/or semi-liquid insults impact materials such asmaterial 10, the liquid and/or semi-liquid matter will tend to spreadrelatively more in the longitudinal direction 28 than the lateraldirection 30. Accordingly, where the major dimension 41 of the openings24 extend substantially in the longitudinal direction 28, there is moreopportunity for the liquid and/or semi-liquid matter to transfer throughthe openings 24 and into any liquid management and holding systemspresent within the absorbent article (e.g. surge materials and/orabsorbent bodies). Some additional benefits may be that the fibers ofthe surrounding the openings 24 may be oriented relatively more in thelongitudinal direction 28, which can enhance a tensile strength of thematerial 10—an important factor in being able to process such materialsin a high-speed converting process.

According to more particular embodiments of the present disclosure, themajor dimension 41 of the openings 24 may form an angle 45 with respectto the longitudinal direction 28 of less than about thirty-five degrees,or less than about twenty-five degrees, or less than about fifteendegrees. Of course, it is not the case that all openings 24 may havetheir major dimension 41 oriented at exactly the same angle 45 withrespect to the longitudinal direction 28. For example, even inembodiments where a majority, or more, of the openings 24 have theirmajor dimension 41 extend substantially in the longitudinal direction28, the specific angles 45 formed by the major dimension 41 ofindividual openings 24 may range between about zero degrees and aboutforty-five degrees.

In still further embodiments, different openings 24 may have their majordimension 41 extend substantially in the longitudinal direction 28 butbe oriented in opposing lateral directions. For example, as can be seenin FIGS. 6A, 6C, and 6D, various of the openings 24 are depicted havingtheir major dimension 41 oriented such that it extends substantially inthe longitudinal direction 28 but toward a first lateral direction. Ascan be seen, other openings 24 which have their major dimension 41extend substantially in the longitudinal direction 28 are oriented suchthat their major dimensions 41 extend toward a second lateral direction,opposite the first lateral direction.

Another feature of the material 110, and other materials contemplated bythe present disclosure, is that the aspect ratios of the openings 24 maybe contained within a certain range. In at least some embodiments of thepresent disclosure, an average aspect ratio of the openings of thematerials of the present disclosure may be between about 1.3 and about3.25, or between about 1.4 and about 3.0, or between about 1.3 and about2.5, or between about 1.3 and about 2.0. These aspect ratio ranges ofthe openings 24 may help to facilitate intake of insulted bodily fluids,particularly in conjunction with the above described orientations of theopenings 24, increasing the overall fluid-handling performance of suchmaterials.

FIG. 6C shows a close-up of a region of the material 110 containing theback edge 27 depicting in greater detail the alignment and orientationof the nodes 12, connecting ligaments 14, and the openings 24 of thematerial 110. It has been found that particular alignments andorientations of the features 12, 14, and 24 are able to producedesirable properties within materials of the present disclosure. Forexample, particular alignments and orientations can help to producedesired tensile strength properties and/or desired necking propertiesfor processability of the materials, while still allowing for ahighly-open material and thus achieving beneficial fluid-handlingproperties. Although such alignments and orientations are described withrespect to the specific pattern of material 110, it should be understoodthat other materials contemplated by the present disclosure may achievesuch described alignments and orientations in other patterns andmaterials.

The pattern of nodes 12, connecting ligaments 14, and openings 24 of thematerial 110 produce series of longitudinally adjacent nodes 12 andlaterally adjacent nodes 12. Nodes 12 are longitudinally adjacent, suchas nodes 12 a and 12 b, if a line 85 drawn between centers C1 and C2does not pass through any openings 24 or other nodes 12 and forms anangle with respect to the longitudinal direction 28 of less thanforty-five degrees. Likewise, nodes 12 are laterally adjacent, such asnodes 12 c and 12 d (or nodes 12 d and 12 e), if a line drawn betweencenters of the nodes 12 c, 12 d does not pass through any openings 24 orany other nodes 12 and forms an angle with respect to the lateraldirection 30 of less than forty-five degrees.

In some embodiments, it may be beneficial for the material 110 to haveone or more lanes 21 of longitudinally adjacent nodes 12 which extendsubstantially in the longitudinal direction 28. Such lanes 21 extendingsubstantially in the longitudinal direction 28 may help to enhance atensile strength of the material 110, thus helping the material 110 tobe able to withstand forces present in a high-speed manufacturingprocess. Lanes 21 which extend substantially in the longitudinaldirection 28 may also help to provide beneficial necking performance ofthe material 110.

A lane 21 comprises a series of connected, longitudinally adjacent nodes12. A lane 21 is considered to extend substantially in the longitudinaldirection 28 where lines drawn between centers of longitudinallyadjacent nodes 12 within a lane 21, such as line 85 drawn betweencenters C1, C2 of nodes 12 a, 12 b, form angles with respect to thelongitudinal dimension 28 of less than about twenty degrees, morepreferably less than about fifteen degrees, even more preferably lessthan about ten degrees, and still even more preferably less than aboutfive degrees. No angle is shown in FIG. 6C because the angle formed byline 85 with respect to the longitudinal direction 28 is zero.

Where lines drawn between centers of two or more nodes 12 and a centerof a connected, longitudinally adjacent reference node 12, each form anangle with respect to the longitudinal direction 28 of less than abouttwenty degrees, the connected, longitudinally adjacent node 12 which isconsidered to be in the lane 21 with the reference node 12 is theconnected, longitudinally adjacent node 12 for which the line drawnbetween its center and the center of the reference node 12 forms thesmaller angle. Where the lines drawn between the centers of theconnected, longitudinally adjacent nodes 12 and a center of thereference node 12 form angles with respect to the longitudinal direction28 which are equal, the lane 21 ends and none of the connected,longitudinally adjacent nodes 12 are considered to be part of thatparticular lane 21 with the reference node 12.

In some embodiments, it may be preferable for the material 110 to haveat least three lanes 21 which extend substantially in the longitudinaldirection 28, or at least four lanes 21 which extend substantially inthe longitudinal direction 28, or at least five lanes 21 which extendsubstantially in the longitudinal direction 28, or at six lanes 21 whichextend substantially in the longitudinal direction 28.

In further embodiments, it may be beneficial for the material 110 tohave a minimum number of lanes 21 which extend substantially in thelongitudinal direction 28 based on a width 33 of the apertured zone 16of the material 110. To help determine as to whether a material such asmaterial 110 has minimum desired number of lanes 21 which extendsubstantially in the longitudinal direction 28, a unitless lane numberratio has been developed. This lane number ratio's value is equal to thewidth 33 of the apertured zone 16 of the material 110, in millimeters,divided by the number of lanes 21 of the material 110 which extendsubstantially in the longitudinal direction 28. It has been found thatmaterials 110 having a lane number ratio value of less than about 15 mayhave sufficient tensile strengths to be suitable for use in high-speedmanufacturing processes. In more preferred embodiments, the lane numberratio may be less than about 12, or less than about 10, or less thanabout 8. Although not desired to encompass all suitable contemplatedembodiments, the lane number ratio may generally be greater than about3, or greater than about 4, or greater than about 5.

The lanes 21 which extend substantially in the longitudinally direction28 have a length 23. The length 23 is the longitudinal length measuredbetween centers of the nodes 12 of the lane 21 extending substantiallyin the longitudinal direction 28 which are disposed most proximate theback edge 27 and the front edge 25 of the material 10 within the lane21. In general, it may be beneficial for the lane 21 extendingsubstantially in the longitudinal direction 28 to extend for a length 23that is greater than about 25% of the overall length L of the material110, or greater than about 50%, or greater than about 75%, or greaterthan about 80%, or greater than about 90% of the overall length L of thematerial 110. In at least some embodiments, the lane 21 extendingsubstantially in the longitudinal direction 28 may extend for the entirelength L of the material 110. Although, it should be understood that notall lanes 21 which extend substantially in the longitudinal direction 28need to extend for such lengths 23. Rather, it may be the case that amajority of the lanes 21 which extend substantially in the longitudinaldirection 28 extend for lengths 23 that are greater than the aboverecited values.

Overall, the alignment of the nodes 12 in the above described mannersmay function to generally align connecting ligaments 14 in thelongitudinal direction 28. For example, the lines 85 drawn betweencenters of longitudinally adjacent nodes 12 may approximate the locationand directions of connecting ligaments 14 which connect suchlongitudinally adjacent nodes 12. By having such lanes 21 which extendsubstantially in the longitudinal direction 28, at least some of theconnecting ligaments 14 of the material 110 may be substantiallylongitudinally aligned. These substantially longitudinally alignedconnecting ligaments 14 may operate to provide the material 110 with thebeneficial tensile strength and/or necking properties as discussedabove.

The material 110 may further have one or more lanes 37 of openings 24which extend substantially in the longitudinal direction 28. Like thelanes 21 of nodes 12, a lane 37 of openings 24 comprises a series oflongitudinally adjacent openings 24. Openings 24 are longitudinallyadjacent where a line drawn between centers of adjacent openings 24spans only a single connecting ligament 13 and forms an angle withrespect to the longitudinal direction 28 of less than about forty-fivedegrees. The centers of the openings 24 may be the geometric centers ofthe openings 24.

A lane 37 is considered to extend substantially in the longitudinaldirection 28 where lines drawn between centers of longitudinallyadjacent openings 24 within a lane 37, such line 77 drawn betweencenters of openings 24 a, 24 b, form angles with respect to thelongitudinal dimension 28 of less than about twenty degrees, morepreferably less than about fifteen degrees, even more preferably lessthan about ten degrees, and still even more preferably less than aboutfive degrees. No angle is shown in FIG. 6C because the angle formed byline 77 with respect to the longitudinal direction 28 is zero degrees.

Where lines drawn between centers of two or more openings 24 and acenter of a longitudinally adjacent reference opening 24, each form anangle with respect to the longitudinal direction 28 of less than abouttwenty degrees, the longitudinally adjacent opening 24 which isconsidered to be in the lane 37 with the reference opening 24 is thelongitudinally adjacent opening 24 for which the line drawn between itscenter and the center of the reference opening 24 forms the smallerangle. Where the lines drawn between the centers of the longitudinallyadjacent openings 24 and a center of the reference opening 24 formangles with respect to the longitudinal direction 28 which are equal,the lane 37 ends and none of the longitudinally adjacent openings 24 areconsidered to be part of that particular lane 37 with the referenceopening 24.

As can be seen in FIG. 6C, the lanes 37 of longitudinally adjacentopenings 24 are laterally offset from the lanes 21 of nodes 12 extendingsubstantially in the longitudinal direction 28. That is, at least withrespect to the lanes 21 of the nodes 12 extending substantially in thelongitudinal direction 28 and lanes 37 of openings 24, there are noopenings 24 disposed longitudinally between longitudinally adjacentnodes 12 and this configuration provides a plurality of connectingligaments 14 that can extend substantially in the longitudinal direction28 and provide the beneficial properties of nonwoven material 110tensile strength and reduced necking noted above.

It may further be beneficial for material 110 where laterally adjacentnodes 12 maintain some degree of longitudinal offset. For example, itmay be beneficial for lines drawn between centers of laterally adjacentnodes 12, such as nodes 12 c and 12 d or nodes 12 d and 12 e, to formangles 19 with respect to the lateral direction 30 of greater than aboutzero degrees. It may more preferable for the angle 19 to be greater thanabout ten degrees, or more preferably greater than about fifteendegrees, or more preferably greater than about twenty degrees. In theseembodiments, the angle 19 may be less than about twenty-five degrees, orless than about twenty degrees, or less than about fifteen degrees. Ofcourse, it is not necessary that all laterally adjacent nodes 12 withinthe material 110 have such a feature whereby a line drawn betweencenters of laterally adjacent nodes 12 forms an angle 19 within thedescribed ranges. In some embodiments, only a majority of the laterallyadjacent nodes 12 may have such a feature whereby a line drawn betweencenters of laterally adjacent nodes 12 forms an angle 19 within thedescribed ranges.

Where the material 110 is a fluid-entangled material, one uniqueproperty of the material 110 is a difference in fiber orientation withinconnecting ligaments 14 which connect longitudinally adjacent nodes 12and connecting ligaments 14 which connect laterally adjacent nodes 12.It has been found that the anisotropy, one measure of the fiberalignment within a connecting ligament 14, of the connecting ligaments14 connecting longitudinally adjacent nodes 12 is generally greater thanabout 1.3, or greater than about 1.4, or greater than about 1.5,according to the Ligament Anisotropy Test Method. In contrast, theanisotropy of the connecting ligaments 14 connecting laterally adjacentnodes 12 is generally less than about than 1.1, or less than about 1.08,or less than about 1.05, according to the Ligament Anisotropy TestMethod. These results indicate that the fibers within the connectingligaments 14 connecting longitudinally adjacent nodes 12 are moregenerally aligned in a similar direction than the fibers within theconnecting ligaments 14 connecting laterally adjacent nodes 12. Thisfeature may further help to lend tensile strength to the material 110 inthe longitudinal direction 28.

The nonwoven material 10 can be comprised of various fibers. In oneembodiment, the nonwoven material 10 can include synthetic fibers andbinder fibers. In preferred embodiments including synthetic fibers andbinder fibers, the binder fibers can provide at least about 5% of theplurality of fibers by total weight of the nonwoven material 10, andmore preferably, at least about 10% of the plurality of fibers by totalweight of the nonwoven material 10. An example of the synthetic fibersthat can be used include polyester fibers, polypropylene fiber, and/orbicomponent fibers of polypropylene and polyethylene, however, it can beappreciated that other fibers may be used without departing from thescope of this disclosure. Exemplary binder fibers that can be used areESC233 binder fibers supplied by FiberVisions, which have a lineardensity of 3 denier, a cut length of 40 mm, and 18 crimps per inch andESC215 binder fibers supplied by FiberVisions, which have a lineardensity of 1.5 denier, a cut length of 40 mm, and 18 crimps per inch.However, it is contemplated that other types of binder fibers may beused.

In some embodiments, the nonwoven material 10 can additionally oralternatively include natural fibers. The fibers of the nonwovenmaterial 10 can be randomly deposited and may be staple length fibers,such as those that are used, for example, in carded webs, airlaid webs,coform webs, etc., and can have a fiber length less than 100 mm, andmore typically in the range of 10-60 mm. Alternatively or additionally,the fibers of the nonwoven material can include more continuous fiberssuch as those that are found in, for example, meltblown or spunbondwebs, and can have a fiber length greater than 100 mm.

In some embodiments, the nonwoven material 10 can be configured as asingle-layered material. In other embodiments, the nonwoven material 10can be configured as a laminate, with the laminate including a precursormaterial to which the nonwoven material 10 can be coupled. An exemplaryprecursor material, which will be described in relation to FIG. 7 inmore detail below, can be a spunbond material.

FIGS. 6F and 6G display alternative embodiments of the nonwoven material210 and 310, respectively. The alternative embodiments demonstrate thatthe nonwoven material 10, 110, 210, 310 can include nodes 12, connectingligaments 14, and openings 24 in a variety of configurations. Thenonwoven materials 110, 210, 310 of FIGS. 6A-6G, respectively, eachinclude an apertured zone 16 and side zones 26 a, 26 b, 26 c, 26 d. Inthe description of the nonwoven materials 110, 210, 310 of FIGS. 6A-6G,respectively, it is to be noted that not all of the nodes 12, connectingligaments 14, and openings 24 are labeled for purposes of clarity.

FIG. 6F demonstrates a nonwoven material 210 that includes an aperturedzone 16 that includes a plurality of nodes 12 that each have fourconnecting ligaments 14 connecting to adjacent nodes 12. Some of theopenings 24 in the nonwoven material 210 can be configured generally inthe shape of a diamond, or may include some curvature to appear in theshape of a lens (biconvex shape with two circular arcs joined at theirendpoints) as illustrated in FIG. 6F. As depicted in FIG. 6F, theopenings 24 can be configured in the same orientation with respect toone another.

Additionally, the embodiment of the nonwoven material 210 depicted inFIG. 6F may be less preferable in some material-handling respects ascompared to the nonwoven material 110 depicted in FIGS. 6A-6D in thatthe nonwoven material 210 does not include lanes 21 of nodes 12extending substantially in the longitudinal direction 28 becauseopenings 24 are disposed between various nodes 12 preventing a series ofnodes 12 to be configured in a lane 21 of nodes 12 extendingsubstantially in the longitudinal direction 28.

FIG. 6G provides yet another exemplary alternative nonwoven material 310that includes an apertured zone 16 that includes a plurality of nodes12. The nonwoven material 310 is configured such that some of the nodes12 (such as node 12 a) have six connecting ligaments 14, while some ofthe nodes 12 (such as node 12 b) have three connecting ligaments 14. Asillustrated in FIG. 6G, the ligaments 14 can be of different thicknessesthan one another. As also illustrated in FIG. 6G, some of the nodes 12can be configured to have a different area than other nodes 12. Theapertured zone 16 also includes a plurality of openings 24. The nonwovenmaterial 310 is configured such that some of the openings 24 (such asopening 24 a) are configured generally in the shape of a hexagon, whilesome of the openings 24 (such as opening 24 b) are configured generallyin the shape of a diamond, or with some curvature to appear in the shapeof a lens. As illustrated in FIG. 6G, the openings 24 can be configuredsuch that some of the openings 24 can provide different areas than oneanother.

FIG. 7A illustrates an exemplary process and apparatus 100′ for how thenonwoven material 10 of the present disclosure may be manufactured. InFIG. 7A, a precursor web 36 is provided that comprises a plurality offibers. The precursor web 36 can be formed from a variety of techniquesof web forming, such as, but not limited to a wet-laying, a foam-laying,or a carding process. In a preferred embodiment as depicted in FIG. 7A,the precursor web 36 can be formed by a wet-laying process through afiber and water slurry 38 being deposited from a drum 40 on a precursorforming surface 42. The precursor forming surface 42 as shown in FIG. 7Acan be a precursor material, such as a spunbond web. However, it iscontemplated that the fiber and water slurry 38 can be depositeddirectly on a belt, screen, or other surface that provides a precursoryforming surface 42. The precursor web 36 can be transferred by a belt 44driven by a drive roll 46, or other transfer devices known by one ofordinary skill in the art. If the precursor web 36 is formed through awet-laying process, the precursor web 36 can be dried through knowntechniques with a dryer 48.

Whether completed off-line or in-line, the precursor web 36 can betransferred to a forming surface 50. The forming surface 50 can be asurface of a texturizing drum 52, such as a forming screen, a portion ofexemplary forming surface 50 being shown in greater detail in FIGS. 8Aand 8B. The texturizing drum 52 can rotate as shown in FIG. 7A and canbe driven by any suitable drive means (not shown) such as electricmotors and gearing as are well known to those of ordinary skill in theart. The material forming the texturizing drum 52 may be any number ofsuitable materials commonly used for such forming drums including, butnot limited to, sheet metal, plastics and other polymer materials,rubber, etc.

FIG. 8A provides a first exemplary embodiments of a portion of a formingsurface 50. The forming surface 50 can include a plurality of formingholes 54, a plurality of projections 56, and a plurality of connectingligament forming areas 69. The connecting ligament forming areas 69 canbe disposed between the plurality of forming holes 54 and the pluralityof projections 56 and can generally be areas of the forming surface 50that are neither a forming hole 54 nor a projection 56.

As will be discussed in more detail below, the geometry, spacing, andorientation of the forming holes 54, the projections 56, and theconnecting ligament forming areas 69 will correspond to the formation ofthe nodes 12, openings 24, and connecting ligaments 14 in the nonwovenmaterial 10. In fact, the alignment and orientation of these formingholes 54, projections 56, and connecting ligament areas 69 can providefor beneficial properties in the formation of the nonwoven materials asdescribed herein. For example, particular alignments and orientationscan help to produce desired tensile strength properties and/or desirednecking properties for processability of the materials, while stillallowing for a highly-open material and thus achieving beneficialfluid-handling properties. Although such alignments and orientations aredescribed with respect to the specific pattern of forming surface 50 inFIG. 8A and forming surface 50′ in FIG. 8B, it should be understood thatother forming surfaces contemplated by the present disclosure mayachieve such described alignments and orientations in other patterns.

As depicted in FIG. 8A, the forming surface 50 can include a pluralityof forming holes 54 that correspond to the shape and pattern of thedesired nodes 12 of the nonwoven material 10. While the forming holes 54depicted in FIG. 8 are round, it should be understood that any number ofshapes and combination of shapes can be used depending on the end useapplication. Examples of additional or alternative possible forming hole54 shapes include, but are not limited to, ovals, crosses, squares,rectangles, diamond shapes, hexagons and other polygons.

The forming holes 54 can be arranged in a plurality of lanes 55 (threelanes 55 labeled in FIG. 8A) that extend in the longitudinal direction57 of the forming surface 50. The longitudinal direction 57 of theforming surface 50 can correspond to a circumferential direction, forexample, if the forming surface 50 is part of a cylindrical texturizingdrum 52. The lanes 55 of forming holes 54 can be formed oflongitudinally adjacent forming holes 54. As discussed above withrespect to the nodes 12 of the nonwoven material 110 depicted in FIGS.6A and 6C, forming holes 54 are longitudinally adjacent if a line 63drawn between centers of forming holes 54 does not pass through anyprojections 56 or any other forming holes 54 and forms an angle withrespect to the longitudinal direction 57 of less than forty-fivedegrees. Similarly, the forming holes 54 can also be arranged in lanesthat extend in the lateral direction 61 of the forming surface 50 if aline drawn between centers of forming holes 54 does not pass through anyprojections 56 or any other forming holes 54 and forms an angle withrespect to the lateral direction 61 of the forming surface 50 of lessthan forty-five degrees.

Where lines drawn between centers of two or more forming holes 54 and acenter of a connected, longitudinally adjacent forming hole 54, eachform an angle with respect to the longitudinal direction 57 of theforming surface 50 of less than about twenty degrees, the connected,longitudinally adjacent forming hole 54 which is considered to be in thelane 55 with the reference forming hole 54 is the connected,longitudinally adjacent forming hole 54 for which the line drawn betweenits center and the center of the reference forming hole 54 forms thesmaller angle. Where the lines drawn between the centers of theconnected, longitudinally adjacent forming holes 54 and a center of thereference forming hole 54 form angles with respect to the longitudinaldirection 57 of the forming surface 57 which are equal, the lane 55 endsand none of the connected, longitudinally adjacent forming holes 54 areconsidered to be part of that particular lane 55 with the referenceforming hole 54.

A lane 55 of forming holes 54 includes a series of connected,longitudinally adjacent forming holes 54. It may be preferable for oneor more lanes 55 of forming holes 54 to be configured to extendsubstantially in the longitudinal direction 57. A lane 55 is consideredto extend in the longitudinal direction when lines (such as line 63)drawn between centers of longitudinally adjacent forming holes 54 formsan angle with respect to the longitudinal direction 57 of less thanabout twenty degrees, more preferably less than about fifteen degrees,even more preferably less than about ten degrees, and still even morepreferably less than about five degrees. No angle is shown in FIG. 8Abecause the angle formed by line 63 with respect to the longitudinaldirection 57 is zero degrees. In some preferred embodiments, a majorityof the plurality of lanes 55 of forming holes 54 that are arranged inthe longitudinal direction 57 can be configured to extend substantiallyin the longitudinal direction 57. Some embodiments, such as thatdepicted in FIG. 8A, may have all the lanes 55 of forming holes 54 onthe forming surface 50 configured in such a fashion.

In some embodiments, it may be preferable for the forming surface 50 tohave at least three lanes 55 of forming holes 54 which extendsubstantially in the longitudinal direction 57 of the forming surface50, or at least four lanes 55 which extend substantially in thelongitudinal direction 57, or at least five lanes 55 which extendsubstantially in the longitudinal direction 57, or at six lanes 55 whichextend substantially in the longitudinal direction 57.

The lanes 55 of forming holes 54 that extend substantially in thelongitudinal direction 57 of the forming surface 50 can have a lengththat spans the entire forming surface 50 or can form only a portion ofthe forming surface 50 length in the longitudinal direction 57 (such asa portion of the circumference of the forming surface 50). For example,in some embodiments, it is contemplated that a single lane 55 of formingholes 54 that extends substantially in the longitudinal direction 57 ofthe forming surface 50 can extend for 5%, or 10%, or 15% or 20%, or 25%or more of a length of the forming surface 50. In some embodiments, thelane 55 of forming holes 54 extending substantially in the longitudinaldirection 57 of the forming surface can extend for less than 95%, orless than 90% or less than 85%, or less than 80%, or less than 75% ofthe length of the forming surface 50. The forming surface 50 can alsoinclude a plurality of projections 56 extending away from an outersurface 58 of the forming surface 50. As depicted in FIG. 8, theprojections 56 can be configured in a pyramidal geometry, however, theprojections 56 can be in various other geometries, cross-sectionalshapes, spacings, and orientations. In some embodiments, the pluralityof projections 56 can decrease in cross-sectional area as they extendfurther away from the outer surface 58 of the forming surface 50. Forexample, the pyramidal shape of the projections 56 depicted in FIG. 8decrease in area the further the projection 56 extends away from theouter surface 58 of the forming surface 50.

Overall, the alignment of the forming holes 54 to form lanes 55 offorming holes 54 extending substantially in the longitudinal direction57 can align connecting ligament forming areas 69 in the longitudinaldirection 57. For example, the lines 63 drawn between centers oflongitudinally adjacent forming holes 54 may approximate the locationand directions of connecting ligament forming areas 69 which connectsuch longitudinally adjacent forming holes 54. By having such lanes 55of forming holes 54 which extend substantially in the longitudinaldirection 57, at least some of the connecting ligament forming areas 69may be substantially longitudinally aligned. These substantiallylongitudinally aligned connecting ligament forming areas 69 can lead toa nonwoven material 110 such as discussed above that can providebeneficial tensile strength and/or necking properties yet maintain anadequate percent open area.

The projections 56 can be arranged in a plurality of lanes 59 (threelanes 59 labeled in FIG. 8A) that extend in the longitudinal direction57 of the forming surface 50. The lanes 59 of projections 56 can beformed of a series of connected, longitudinally adjacent projections 56.As discussed above with respect to the openings 24 in the nonwovenmaterial 110 depicted in FIGS. 6A and 6C, projections 56 arelongitudinally adjacent where a line (such as line 65 a or 65 b in FIG.8A) does not pass through any forming holes 54 or any other projections56 and spans across only a single connecting ligament forming area 69and forms an angle with respect to the longitudinal direction 57 of theforming surface 50 of less than about forty-five degrees. The centers ofthe projections 56 may be the geometric centers of the projections 56.Similarly, the projections 56 can also be laterally adjacent when if aline drawn between centers of projections 56 does not pass through anyforming holes 54 or any other projections 56 and the line only spansacross a single connecting ligament forming area 69 and forms an anglewith respect to the lateral direction 61 of the forming surface 50 ofless than forty-five degrees.

In some embodiments, a majority of the plurality of lanes 59 ofprojections 56 extending in the longitudinal direction 57 are laterallyoffset from a nearest adjacent lane 55 of forming holes 54 extendingsubstantially in the longitudinal direction 57. With such aconfiguration, such as depicted in FIG. 8A (as well as in an alternativeembodiment depicted in FIG. 8B), the connecting ligament forming areas69 disposed between forming holes 54 can extend substantially in thelongitudinal direction 57. As a result, nonwoven materials 10 formedfrom such a forming surface 50 can have connecting ligaments 14 thatextend substantially in the longitudinal direction 28 of the nonwovenmaterial 110, such as described above with respect to nonwoven material110 in FIGS. 6A and 6C. As noted above, this can provide beneficialproperties of improved tensile strength and reduced necking of thenonwoven material 110 while maintaining a desirable percent open area ofthe apertured zone 16 of the nonwoven material 110.

In some embodiments, the projections 56 within each lane 59 can beconfigured such that longitudinally adjacent projections 56 can form aline 65 a or 65 b that forms an angle 67 a, 67 b, respectively, with thelongitudinal direction 57. In some embodiments, this angle 67 a or 67 bcan be between 15 degrees to 60 degrees. As depicted in FIG. 8A,longitudinally adjacent projections 56 within a lane 59 of projections56 can form a zig-zag type pattern in the longitudinal direction 57 suchthat each projection 56 within a single lane 59 of projections 56 islaterally offset in the lateral direction 61 from its prior projection56 and its successive projection 56 in the lane 59 in the same lateraldirection 61.

However, in some preferred embodiments such as the embodiment depictedin the detailed top view of an alternative forming surface 50′ in FIG.8B, the forming surface 50′ can be configured to include one or morelanes 59 of projections 56 that extend substantially in the longitudinaldirection 57. A lane 59 is considered to extend in the longitudinaldirection when lines (such as line 65) drawn between centers oflongitudinally adjacent projections 56 forms an angle with respect tothe longitudinal direction 57 of less than about twenty degrees, morepreferably less than about fifteen degrees, even more preferably lessthan about ten degrees, and still even more preferably less than aboutfive degrees. No angle is shown in FIG. 8B because the angle formed byline 65 with respect to the longitudinal direction 57 is zero degrees.In some embodiments, a majority of the plurality of lanes 59 ofprojections 56 extending in the longitudinal direction 57 are configuredto extend substantially in the longitudinal direction 57. And in someembodiments, substantially all or all of the plurality of lanes 59 ofprojections 56 can be configured in this manner.

Still referring to FIG. 8B, each projection 56 can include a length 73and a width 75. The length 73 can also be referred to as the majordimension for the projection 56 and the width 75 can be referred to asthe minor dimension for the projection 56. As noted above, the length 73compared to the width 75 of the projection 56 can result in forming anaspect ratio for an opening 24 in the nonwoven material 110, asdiscussed above with respect FIG. 6D. Preferably, an aspect ratio of thelength 73 to the width 75 of the projection 56 is greater than 1.0. Insome embodiments, the aspect ratio of the length 73 to the width 75 ofthe projection 56 is from about 1.3 and about 3.25, or between about 1.4and about 3.0, or between about 1.3 and about 2.5, or between about 1.3and about 2.0 In some embodiments, the length 73 of the projection 56can be oriented such that the length 75 extends substantially in thelongitudinal direction 57 of the forming surface 50. As used herein, aprojection 56 having its length 73 oriented in the longitudinaldirection 57 is meant to encompass projections 56 having a direction oftheir length 73 form an angle of less than 45 degrees with thelongitudinal direction 57 of the forming surface 50. In someembodiments, such as shown in FIG. 8B, a plurality of the projections 56within a lane 59 can be configured in such a manner. In someembodiments, substantially all or all of the projections 56 within alane 59 of projections 56 can be configured in such a manner. As alsodepicted in FIG. 8B, adjacent lanes 59 of projections 56 can beconfigured such that the angular orientation of the major dimension (orlength 73) of projections 56 are oriented in different lateraldirections. For example, the left-most lane 59 of projections 56 hasprojections 56 with their length 73 being oriented in a first lateraldirection whereas the second lane 59 of projections 56 has projections56 with their length 73 being oriented in a second lateral directionthat is opposite the first lateral direction. In some embodiments, theprojections 56 in adjacent lanes 59 of projections 56 can be configuredto have the projections 56 oriented such that their lengths 73 extend inlateral directions that are mirror images of one another.

The forming surface 50 can also include one or more areas 60 a, 60 bthat are substantially free from projections 56. The areas 60 a, 60 b,as will be discussed in further detail below, can correspond to the sidezones 26 a, 26 b in the nonwoven material 10. In some embodiments, theareas 60 a, 60 b corresponding to the side zones 26 a, 26 b can includeapertures 71. However, in preferred embodiments, if included, theapertures 71 in the areas 60 a, 60 b are smaller in cross-sectional areathan the forming holes 54 in the forming surface 50 and can help withfluid removal during the fluid entangling process. For example, anaverage area of the apertures 71 in the areas 60 a, 60 b can be lessthan an average area of the forming holes 54 in the forming surface 50.The apertures 71 in the areas 60 a, 60 b can lead to formation ofmicro-bumps 13, as depicted in FIG. 6B. The area of the outer surface 58of the forming surface 50 between the apertures 71 in zones 60 a, 60 bcan form micro-apertures 81 and/or areas of lower fiber density 39.

Referring back to FIG. 7A, typically, the perforated forming surface 50is removably fitted onto and over an optional porous inner drum shell 62so that different forming surfaces 50 can be used for different endproduct designs. The porous inner drum shell 62 interfaces with a fluidremoval system 64 which facilitates pulling the entangling fluid andfibers down into the forming holes 54 in the forming surface 50, therebyforming the nodes 12 in the nonwoven material 10. The porous inner drumshell 62 also acts as a barrier to retard further fiber movement downinto the fluid removal system 60 and other portions of the equipmentthereby reducing fouling of the equipment. The porous inner drum shell62 rotates in the same direction and at the same speed as thetexturizing drum 52. In addition, to further control the height of thenodes 12 on the nonwoven material 10, the distance between the innerdrum shell 62 and the outer surface 58 of the forming surface 50 can bevaried. Generally, the spacing between the outer surface 58 of theforming surface 50 and the outer surface of the inner drum shell 64 willrange between about 0 and about 5 mm. Other ranges can be used dependingon the particular end-use application and the desired features of thenonwoven material 10.

The depth of the forming holes 54 in the texturizing drum 52 or otherprojection forming surface 50 can be between 1 mm and 10 mm butpreferably between around 3 mm and 6 mm to produce nodes 12 with theshape most useful in the expected common applications. The forming hole54 cross-section diameter (or major dimension) may be between about 2 mmand 10 mm but it is preferably between 3 mm and 6 mm as measured alongthe major axis and the spacing of the forming holes 54 on acenter-to-center basis can be between 3 mm and 10 mm but preferablybetween 4 mm and 7 mm. The pattern of the spacing between forming holes54 may be varied and selected depending upon the particular end use.Some examples of patterns include, but are not limited to, alignedpatterns of rows and/or columns, skewed patterns, hexagonal patterns,wavy patterns and patterns depicting pictures, figures and objects.

The cross-sectional dimensions of the forming holes 54 and their depthinfluence the cross-section and height of the nodes 12 produced in thenonwoven material 10. Generally, forming hole 54 shapes with sharp ornarrow corners at the leading edge of the forming holes 54 as viewed inthe machine direction should be avoided as they can sometimes impair theability to safely remove the nonwoven material 10 from the formingsurface 50 without damage to the nodes 12. In addition, thethickness/hole depth in the forming surface 50 will generally tend tocorrespond to the depth or height of the nodes 12 in the nonwovenmaterial 10. It should be noted, however, that each of the hole depth,spacing, size, shape and other parameters may be varied independently ofone another and may be varied based upon the particular end use of thenonwoven material 10 being formed.

Not to be bound by theory, but it is believed that specific aspectratios of the depth of the forming holes 54 to the diameter (or majordimension) of the forming holes 54 contribute to increased anisotropy ofthe nodes 12 in the nonwoven material 10. The term “major dimension” isused in the context if the forming holes 54 are not circular in shape,for example, if the forming holes 54 are shaped as an ellipse, the majordimension would be the length of the ellipse along its major axis. It isbelieved that an aspect ratio of the depth of a forming hole 54 to thediameter (or major dimension) of the forming hole 54 greater than 1.0 isbelieved to lead to increased anisotropy of the nodes 12 of the nonwovenmaterial 10. In some preferred embodiments, the aspect ratio of thedepth of the forming holes 54 to the diameter (or major dimension) ofthe forming holes 54 can be between from 1.0 to 1.2.

As noted above, increased anisotropy in the nodes 12 in the nonwovenmaterial 10 can provide improved compression properties of the nonwovenmaterial 10.

In the embodiment depicted in FIG. 7A, the forming surface 50 is shownin the form of a forming screen placed on a texturizing drum 52. Itshould be appreciated however that other means may be used to create theforming surface 50. For example, a foraminous belt or wire (not shown)may be used which includes forming holes 54 formed in the belt or wireat appropriate locations. Alternatively, flexible rubberized belts (notshown) which are impervious to the pressurized fluid entangling streamsexcept in the location of the forming holes 54 may be used. Such beltsand wires are well known to those of ordinary skill in the art as arethe means for driving and controlling the speed of such belts and wires.A texturizing drum 52 is more advantageous for formation of the nonwovenmaterial 10 according to the present disclosure because it can be madewith an outer surface 58 between the forming holes 54 and projections 56that is smooth and impervious to entangling fluid, and which does notleave a wire weave pattern on the nonwoven material 10 as wire beltstend to do.

In embodiments where the forming surface 50 forms a portion of atexturizing drum 52 as a forming screen, the forming surface 50 and itsfeatures can be achieved through using a variety of techniques. Forexample, the forming surface 50 and its features of forming holes 54 andprojections 56 can be formed by casting, molding, punching, stamping,machining, laser-cutting, water jet cutting, and 3D printing, or anyother suitable methodology.

The exemplary apparatus and method 100′ can also include one or morefluid entangling devices 66. The most common fluid used in this regardis referred to as spunlace or hydroentangling technology which usespressurized water as the fluid for entanglement. As such, the fluidentangling device 66 can include a plurality of high pressure fluid jets(not shown) to emit a plurality of pressurized fluid streams 68. Thesefluid streams 68, which are preferably water, can be directed towardsthe precursor web 36 on the forming surface 50 and can cause the fibersto be further entangled within nonwoven material 10 and/or the precursorforming surface 42 (in the case the precursor forming surface is anunderlying web of material). The fluid streams 68 can also cause thefibers in the precursor web 36 to be directed into the forming holes 54and out of the base plane 18 of the first surface 20 of the nonwovenmaterial 10 and into the Z-direction 38 perpendicular to the base plane18 to form the nodes 12 in the nonwoven material 10 (see FIGS. 2 and 3).The fluid streams 68 can also provide for at least a majority of theplurality of nodes 12 to be configured such that they have an anisotropyvalue greater than 1.0, as previously discussed above. The fluid streams68 can also cause the fibers in the precursor web 36 to be directedaround the projections 56 on the forming surface 50 into the connectingligament forming areas 69 to form the plurality of connecting ligaments14 and the plurality of openings 24 on the nonwoven material 10.

In FIG. 7A a single fluid entangling device 66 is shown, however,depending on the level of entanglement needed and the particulardimensions and qualities of the nonwoven material 10 desired, aplurality of such fluid entangling devices 66 can be used. Theentangling fluid streams 68 of the fluid entangling devices 66 emanatesfrom injectors via jet packs or strips (not shown) consisting of a rowor rows of pressurized fluid jets with small apertures of a diameterusually between 0.08 and 0.15 mm and spacing of around 0.5 mm in thecross-machine direction. The pressure in the jets can be between about 5bar and about 400 bar but typically is less than 200 bar except forheavy nonwoven materials 10 and when fibrillation is required. Other jetsizes, spacings, numbers of jets and jet pressures can be used dependingupon the particular end application. Such fluid entangling devices 66are well known to those of ordinary skill in the art and are readilyavailable from such manufacturers as Fleissner of Germany andAndritz-Perfojet of France.

The fluid entangling devices 66 will typically have the jet orificespositioned or spaced between about 5 mm and about 20 mm, and moretypically between about 5 and about 10 mm from the forming surface 50though the actual spacing can vary depending on the basis weights of thematerials being acted upon, the fluid pressure, the number of individualjets being used, the amount of vacuum being used via the fluid removalsystem 64 and the speed at which the equipment is being run.

In the embodiment shown in FIG. 7A, the fluid entangling device 66 is aconventional hydroentangling device the construction and operation ofwhich is well known to those of ordinary skill in the art, such as, forexample, U.S. Pat. No. 3,485,706 to Evans, the contents of which isincorporated herein by reference in its entirety for all purposes. Alsosee the description of the hydraulic entanglement equipment described byHoneycomb Systems, Inc., Biddeford, Me., in the article entitled “RotaryHydraulic Entanglement of Nonwovens”, reprinted from INSIGHT '86INTERNATIONAL ADVANCED FORMING/BONDING Conference, the contents of whichis incorporated herein by reference in its entirety for all purposes.

The speed of the rotation of the drive roll 46 and the texturizing drum52 can be set at various speeds with respect to one another. In someembodiments, the speed of the rotation of the drive roll 46 and thetexturizing drum 52 can be the same. In other embodiments, the speed ofthe rotation of the drive roll 46 and the texturizing drum 52 can bedifferent. For example, in some embodiments, the speed of thetexturizing drum 52 may be less than the speed of the drive roll 46 toprovide for overfeeding of the precursor web 36 on the forming surface50 on the texturizing drum 52. Such overfeeding can be used to providevaried properties in the nonwoven material 10, such as, improvedformation of nodes 12 in the nonwoven material 10 and increased heightof the nodes 12.

After the fluid entanglement occurs from the fluid entangling streams 68by the fluid entanglement device 66, the precursor web 36 becomes ahydroentangled web forming the nonwoven material 10 described above thatincludes a plurality of nodes 12, a plurality of connecting ligaments 14interconnecting the plurality of nodes 12, and a plurality of openings24 as described above. The apparatus 100′ and process can furtherinclude removing the hydroentangled web of nonwoven material 10 from theforming surface 50 and drying the hydroentangled web to provide athree-dimensional nonwoven material 10. Drying of the nonwoven material10 can occur through known techniques by one of ordinary skill in theart. In embodiments where the precursory web includes binder fibers, thedrying of the nonwoven material 10 can activate the binder fibers.Activating the binder fibers can assist with the preservation of thethree-dimensionality of the nonwoven material 10 by helping to preservethe geometry and height of the nodes 12 that extend away from the baseplane 18 on the first surface 20 of the nonwoven material 10 (asdepicted in FIGS. 2 and 3).

FIG. 7B provides an alternative configuration of an apparatus and method100″ for manufacturing the nonwoven material 10 as described herein. InFIG. 7B, the apparatus and method 100″ can include a support web 43 thatis brought into contact with the precursor web 36 prior to thefluid-entangling unit 66. By separating the precursor web 36 from thesupport web 43, different feeding options of the precursor web 36 andthe support web 43 can be achieved. For example, the precursor web 36can be overfed to the fluid-entangling unit 66 through sizes and speedsof drive roll 46 in comparison to the texturizing drum 52, whereas thesupport web 43 can be supplied to the fluid-entangling unit 66 at amatch speed of the texturizing drum 52 through drive roll 47. This isfurther described in U.S. Pat. No. 9,474,660 invented by Kirby, Scott S.C. et al., which is incorporated herein in its entirety to the extentnot contradictory herewith.

As also depicted in FIG. 7C, in some embodiments, the nonwoven material10 can be combined with an additional web, such as a carrier material151. The carrier material 151 can be coupled to the nonwoven material 10through any suitable coupling mechanism, such as by adhesive bonding ormechanical bonding, for example, ultrasonic bonding, pressure bonding,thermal bonding, or any other suitable bonding mechanism. In somepreferred embodiments, the carrier material 151 is bonded to thenonwoven material 10 in the first and second side zones 26 a, 26 b ofthe nonwoven material 10, but not in the apertured zone 16 of thenonwoven material. The carrier material 151 can be coupled to thenonwoven material 10 after the fluid-entangling unit 66. In someembodiments, the carrier material 151 can be coupled to the nonwovenmaterial 10 after the nonwoven material 10 is dried. In otherembodiments, the carrier material 151 can be coupled to the nonwovenmaterial 10 before the nonwoven material 10 is dried. The carriermaterial 151 can provide additional tensile strength to the nonwovenmaterial 10 and can improve its handling in high speed converting and/ormanufacturing environments. The carrier material 151 is preferably aliquid permeable material and is coupled to the nonwoven material 10such that the carrier material 151 adjoins the first surface 20 of thenonwoven material 10 including the nodes 12, as shown best in FIG. 7D.It is also noted that a carrier material 151 could be added to theapparatus 100″ and process as depicted and described with respect toFIG. 7B in which a support web 43 is supplied to the fluid entanglingunit 66 separate from the precursor web 36.

FIG. 7D depicts a cross-section of the nonwoven material 10 and carriermaterial 151 as viewed along line 7D-7D of FIG. 7C. As shown in FIG. 7D,the nonwoven material 10 coupled to the carrier material 151 can have afirst surface 155 and a second surface 157. In the particular embodimentshown in FIG. 7D, the material 10 is coupled to the carrier sheet 151 inan orientation where the nodes 12 of the material 10 extend from a baseplane 18 of the material 10, such as from the first surface 20, towardthe second surface 157 of the carrier material 10. However, in otherembodiments, other orientations of the material 10 and the carriermaterial 151 are contemplated.

In some embodiments, the carrier material 151 may have a width that isgreater than the width 35 of the material 10, such as shown in FIG. 7D.Such configurations may be desirable where the laminate of the material10 and the carrier material 151 is used as a liner in an absorbentarticle. In such embodiments, the material 10 can be localized over anabsorbent body of the article, while the carrier material 151 may spanfully between the edges of a chassis of the absorbent article. However,in other embodiments, the width of the carrier material 151 may be equalto the width of the material 10. Various configurations of the nonwovenmaterial of the present disclosure, such as material 10, and thesecondary material, such as carrier material 151, disposed within anabsorbent article are described in more detail below with respect toFIGS. 11A-14.

The carrier material 151 can comprise any suitable nonwoven material,such as a spunbond material, a meltblown material, aspunbond-meltblown-spunbond (SMS) material, a spunlace material, or thelike. The carrier material 151 may generally have a basis weight ofbetween about 30 gsm and about 100 gsm. Combined, the carrier material151 may provide the material 10 with increased strength to allow thematerial 10 to be processed in high-speed manufacturing processes. In atleast some embodiments the carrier material 151 may contributebeneficially to fluid handling properties of the material 10.

The carrier material 151 may be coupled to the material 10 withinbonding regions 153. In at least some embodiments, the material 10 iscoupled to the carrier material 151 only within the bonding regions 153.As seen, these bonding regions 153 can be disposed within the side zones26 a, 26 b of the material 10. In some embodiments the bonding regions153 can be co-extensive with the side zones 26 a, 26 b. Although, inother embodiments, such as shown in FIG. 7D, the bonding regions 153 canbe narrower than the side zones 26 a, 26 b. The material 10 and thecarrier material 151 may be bonded through mechanical bonding methodssuch as heat bonding, ultrasonic bonding, pressure bonding, or the like.Alternatively, the material 10 and the carrier material 151 may bebonded with adhesive.

However, in other embodiments, the material 10 may be further bonded tothe carrier material 151 within bonding regions 153 as well as withinthe apertured zone 16 of the material 10. For example, adhesive maybeapplied to the carrier material 151 in regions which come into contactwith the apertured zoned 16 of the material 10. In such embodiments, thenodes 12 of the material 10 may additionally be bonded to the carriersheet 151 along with at least portions of the side zones 26 a, 26 b.

Although FIGS. 7A-7C display exemplary apparatuses 100′, 100″, and 100′″and methods of fluid entanglement for manufacturing the nonwovenmaterial 10, it is contemplated that variances from these apparatuses100′, 100″, and 100′ and fluid entanglement processes can be used. Forexample, as mentioned previously, the precursor web 36 can be providedutilizing various techniques other than a wet-laying process, such asbeing formed by a foam-laying process or a carding process.Additionally, the precursor web 36 can be provided on a separate lineand wound onto core rolls (not shown) and then transported to a separatemanufacturing line to engage in the fluid entanglement process by afluid entangling device 66 as discussed above.

Absorbent Article:

In one of its many potential uses, the nonwoven material 10 as describedabove may be incorporated into an absorbent article 410. Referring toFIGS. 9-11, a non-limiting illustration of an absorbent article 410, forexample, a diaper, is illustrated. Other embodiments of the absorbentarticle could include training pants, youth pants, adult incontinencegarments, and feminine hygiene articles. While the embodiments andillustrations described herein may generally apply to absorbent articlesmanufactured in the product longitudinal direction, which is hereinaftercalled the machine direction manufacturing of a product, it should benoted that one of ordinary skill in the art could apply the informationherein to absorbent articles manufactured in the latitudinal directionof the product, which hereinafter is called the cross directionmanufacturing of a product, without departing from the spirit and scopeof the disclosure.

The nonwoven material 10 of the present disclosure can form one or morecomponents, or one or more portions of components, of the absorbentarticle 410 as described below. In the exemplary embodiment describedbelow and illustrated in FIGS. 9-11, the nonwoven material 10 can formthe bodyside liner 428 of the absorbent article 410. However, as statedabove, it is contemplated that the nonwoven material 10 can additionallyor alternatively form other components, or other portions of componentsof the absorbent article 410, including, but not limited to, the outercover 426, a fluid transfer layer 446, a fluid acquisition layer 448, awaist containment member 454, and/or a component of the fasteningsystem, such as a front fastener 492.

The absorbent article 410 illustrated in FIG. 9 can include a chassis11. The absorbent article 410 can include a front waist region 412, arear waist region 414, and a crotch region 416 disposed between thefront waist region 412 and the rear waist region 414 and interconnectingthe front and rear waist regions, 412, 414, respectively. The frontwaist region 412 can be referred to as the front end region, the rearwaist region 414 can be referred to as the rear end region, and thecrotch region 416 can be referred to as the intermediate region.

As illustrated in FIGS. 9 and 10, the absorbent article 410 can have apair of longitudinal side edges 418, 420, and a pair of opposite waistedges, respectively designated front waist edge 422 and rear waist edge424. The front waist region 412 can be contiguous with the front waistedge 422 and the rear waist region 414 can be contiguous with the rearwaist edge 424. The longitudinal side edges 418, 420 can extend from thefront waist edge 422 to the rear waist edge 424. The longitudinal sideedges 418, 420 can have portions that are curved between the front waistedge 422 and the rear waist edge 424 as depicted in FIG. 10, while inother embodiments may be configured to extend in a direction parallel tothe longitudinal direction 430 for their entire length.

The front waist region 412 can include the portion of the absorbentarticle 410 that, when worn, is positioned at least in part on the frontof the wearer while the rear waist region 414 can include the portion ofthe absorbent article 410 that, when worn, is positioned at least inpart on the back of the wearer. The crotch region 416 of the absorbentarticle 410 can include the portion of the absorbent article 410 that,when worn, is positioned between the legs of the wearer and canpartially cover the lower torso of the wearer. The waist edges, 422 and424, of the absorbent article 410 are configured to encircle the waistof the wearer and together define a central waist opening 423 (aslabeled in FIG. 9) for the waist of the wearer. Portions of thelongitudinal side edges 418, 420 in the crotch region 416 can generallydefine leg openings for the legs of the wearer when the absorbentarticle 410 is worn.

The absorbent article 410 can include an outer cover 426 and a bodysideliner 428. The outer cover 426 and the bodyside liner 428 can form aportion of the chassis 411. In an embodiment, the bodyside liner 428 canbe bonded to the outer cover 426 in a superposed relation by anysuitable means such as, but not limited to, adhesives, ultrasonic bonds,thermal bonds, pressure bonds, or other conventional techniques. Theouter cover 426 can define a length in a longitudinal direction 430, anda width in the lateral direction 432, which, in the illustratedembodiment, can coincide with the length and width of the absorbentarticle 410.

The chassis 411 can include an absorbent body 434. The absorbent body434 can be disposed between the outer cover 426 and the bodyside liner428. In an embodiment, the absorbent body 434 can have a length andwidth that are the same as or less than the length and width of theabsorbent article 410. The bodyside liner 428, the outer cover 426, andthe absorbent body 434 can form part of an absorbent assembly 444. Theabsorbent assembly 444 can also include a fluid transfer layer 446(shown in FIGS. 10 and 11) and a fluid acquisition layer 448 (shown inFIGS. 10 and 11) between the bodyside liner 428 and the absorbent body434. In some embodiments, if a fluid transfer layer 446 is present, theacquisition layer 448 can be between the bodyside liner 428 and thefluid transfer layer 446 as is known in the art. The absorbent assembly444 can also include a spacer layer (not shown) disposed between theabsorbent body 434 and the outer cover 426 as is known in the art. Theabsorbent assembly 444 can include other components in some embodiments.It is also contemplated that some embodiments may not include a fluidtransfer layer 446, and/or an acquisition layer 448, and/or a spacerlayer.

The absorbent article 10 can be configured to contain and/or absorbliquid, solid, and semi-solid body exudates discharged from the wearer.In some embodiments, a pair of containment flaps (not shown) can beconfigured to provide a barrier to the lateral flow of body exudates. Insome embodiments, the absorbent article 410 can further include legelastic members (not shown) as are known to those skilled in the art. Insome embodiments, the absorbent article 10 can include a waistcontainment member 454. The waist containment member 454 can be disposedin the rear waist region 414 of the absorbent article 410. Although notdepicted herein, it is contemplated that the waist containment member454 can be additionally or alternatively disposed in the front waistregion 412 of the absorbent article 410.

Additional details regarding each of these elements of the absorbentarticle 10 described herein can be found below and with reference to theFIGS. 1 through 7.

Outer Cover:

The outer cover 426 and/or portions thereof can be breathable and/orliquid impermeable. The outer cover 426 and/or portions thereof can beelastic, stretchable, or non-stretchable. The outer cover 426 may beconstructed of a single layer, multiple layers, laminates, spunbondfabrics, films, meltblown fabrics, elastic netting, microporous webs,bonded-carded webs or foams provided by elastomeric or polymericmaterials. In an embodiment, for example, the outer cover 426 can beconstructed of a microporous polymeric film, such as polyethylene orpolypropylene.

In an embodiment, the outer cover 426 can be a single layer of a liquidimpermeable material, such as a polymeric film. In an embodiment, theouter cover 426 can be suitably stretchable, and more suitably elastic,in at least the lateral direction 432 of the absorbent article 410. Inan embodiment, the outer cover 26 can be stretchable, and more suitablyelastic, in both the lateral 432 and the longitudinal 430 directions. Inan embodiment, the outer cover 426 can be a multi-layered laminate inwhich at least one of the layers is liquid impermeable. In someembodiments, the outer cover 426 can be a two layer construction, whichtwo layers can be bonded together such as by a laminate adhesive.Suitable laminate adhesives can be applied continuously orintermittently as beads, a spray, parallel swirls, or the like, but itis to be understood that the inner layer can be bonded to the outerlayer by other bonding methods, including, but not limited to,ultrasonic bonds, thermal bonds, pressure bonds, or the like.

The outer layer of the outer cover 426 can be any suitable material andmay be one that provides a generally cloth-like texture or appearance tothe wearer. An example of such material can be a 100% polypropylenebonded-carded web with a diamond bond pattern available from Sandler A.G., Germany, such as 30 gsm Sawabond 4185® or equivalent. Anotherexample of material suitable for use as an outer layer of an outer cover426 can be a 20 gsm spunbond polypropylene non-woven web. The outerlayer may also be constructed of the same materials from which thebodyside liner 428 can be constructed as described herein.

The liquid impermeable inner layer of the outer cover 426 (or the liquidimpermeable outer cover 426 where the outer cover 426 is of asingle-layer construction) can be either vapor permeable (i.e.,“breathable”) or vapor impermeable. The liquid impermeable inner layer(or the liquid impermeable outer cover 426 where the outer cover 426 isof a single-layer construction) can be manufactured from a thin plasticfilm. The liquid impermeable inner layer (or the liquid impermeableouter cover 426 where the outer cover 426 is of a single-layerconstruction) can inhibit liquid body exudates from leaking out of theabsorbent article 410 and wetting articles, such as bed sheets andclothing, as well as the wearer and caregiver.

In some embodiments, where the outer cover 426 is of a single layerconstruction, it can be embossed and/or matte finished to provide a morecloth-like texture or appearance. The outer cover 426 can permit vaporsto escape from the absorbent article 410 while preventing liquids frompassing through. A suitable liquid impermeable, vapor permeable materialcan be composed of a microporous polymer film or a non-woven materialwhich has been coated or otherwise treated to impart a desired level ofliquid impermeability.

Absorbent Body:

The absorbent body 434 can be suitably constructed to be generallycompressible, conformable, pliable, non-irritating to the wearer's skinand capable of absorbing and retaining liquid body exudates. Theabsorbent body 434 can be manufactured in a wide variety of sizes andshapes (for example, rectangular, trapezoidal, T-shape, I-shape,hourglass shape, etc.) and from a wide variety of materials. The sizeand the absorbent capacity of the absorbent body 434 should becompatible with the size of the intended wearer (infants to adults) andthe liquid loading imparted by the intended use of the absorbent article410. The absorbent body 434 can have a length and width that can be lessthan or equal to the length and width of the absorbent article 410.

The absorbent body 434 includes absorbent material. In an embodiment,the absorbent body 434 can be composed of a web material of hydrophilicfibers, cellulosic fibers (e.g., wood pulp fibers), natural fibers,synthetic fibers, woven or nonwoven sheets, scrim netting or otherstabilizing structures, superabsorbent material, binder materials,surfactants, selected hydrophobic and hydrophilic materials, pigments,lotions, odor control agents or the like, as well as combinationsthereof. In an embodiment, the absorbent body 434 can be a matrix ofcellulosic fluff and superabsorbent material. In an embodiment, theabsorbent body 434 may be constructed of a single layer of materials, orin the alternative, may be constructed of two or more layers ofmaterials.

Various types of wettable, hydrophilic fibers can be used in theabsorbent body 434.

Examples of suitable fibers include natural fibers, cellulosic fibers,synthetic fibers composed of cellulose or cellulose derivatives, such asrayon fibers; inorganic fibers composed of an inherently wettablematerial, such as glass fibers; synthetic fibers made from inherentlywettable thermoplastic polymers, such as particular polyester orpolyamide fibers, or composed of nonwettable thermoplastic polymers,such as polyolefin fibers which have been hydrophilized by suitablemeans. The fibers may be hydrophilized, for example, by treatment with asurfactant, treatment with silica, treatment with a material which has asuitable hydrophilic moiety and is not readily removed from the fiber,or by sheathing the nonwettable, hydrophobic fiber with a hydrophilicpolymer during or after formation of the fiber. Suitable superabsorbentmaterials can be selected from natural, synthetic, and modified naturalpolymers and materials. The superabsorbent materials can be inorganicmaterials, such as silica gels, or organic compounds, such ascross-linked polymers. In an embodiment, the absorbent body 434 can befree of superabsorbent material.

If a spacer layer is present, the absorbent body 434 can be disposed onthe spacer layer and superposed over the outer cover 426. The spacerlayer can be bonded to the outer cover 426, for example, by adhesive. Insome embodiments, a spacer layer may not be present and the absorbentbody 434 can directly contact the outer cover 426 and can be directlybonded to the outer cover 426. However, it is to be understood that theabsorbent body 434 may be in contact with, and not bonded with, theouter cover 426 and remain within the scope of this disclosure. In anembodiment, the outer cover 426 can be composed of a single layer andthe absorbent body 434 can be in contact with the singer layer of theouter cover 426. In some embodiments, at least a portion of a layer,such as but not limited to, a fluid transfer layer 446 and/or a spacerlayer, can be positioned between the absorbent body 434 and the outercover 426. The absorbent body 434 can be bonded to the fluid transferlayer 446 and/or the spacer layer.

Bodyside Liner:

The bodyside liner 428 of the absorbent article 410 can overlay theabsorbent body 434 and the outer cover 426 and can be configured toreceive insults of exudates from the wearer and can isolate the wearer'sskin from liquid waste retained by the absorbent body 434. The bodysideliner 428 can from at least a part of the body facing surface 419 of thechassis 411 configured to be against a wearer's skin.

In various embodiments, a fluid transfer layer 446 can be positionedbetween the bodyside liner 428 and the absorbent body 434 (as shown inFIG. 11). In various embodiments, an acquisition layer 448 can bepositioned between the bodyside liner 428 and the absorbent body 434 ora fluid transfer layer 446, if present (as shown in FIG. 11). In variousembodiments, the bodyside liner 428 can be bonded to the acquisitionlayer 448, or to the fluid transfer layer 446 if no acquisition layer448 is present, via adhesive and/or by a point fusion bonding. The pointfusion bonding may be selected from ultrasonic, thermal, pressurebonding, and combinations thereof.

In an embodiment, the bodyside liner 428 can extend beyond the absorbentbody 434 and/or a fluid transfer layer 446, if present, and/or anacquisition layer 448, if present, and/or a spacer layer, if present, tooverlay a portion of the outer cover 426 and can be bonded thereto byany method deemed suitable, such as, for example, by being bondedthereto by adhesive, to substantially enclose the absorbent body 434between the outer cover 426 and the bodyside liner 428. In someembodiments, the bodyside liner 428 and the outer cover 426 may be ofthe same dimensions in width and length. In some embodiments, however,the bodyside liner 428 may be narrower than the outer cover 426 and/orshorter than the outer cover 426. In some embodiments, the length of thebodyside liner 428 can range from 50%-100% of the length of theabsorbent article 410 as measured in a direction parallel to thelongitudinal direction 430. In some embodiments, the bodyside liner 428can be of greater width than the outer cover 426. It is alsocontemplated that the bodyside liner 428 may not extend beyond theabsorbent body 434 and/or may not be secured to the outer cover 426. Insome embodiments, the bodyside liner 428 can wrap at least a portion ofthe absorbent body 434, including wrapping around both longitudinaledges of the absorbent body 434, and/or one or more of the end edges ofthe absorbent body 434. It is further contemplated that the bodysideliner 428 may be composed of more than one segment of material.

The bodyside liner 428 can be of different shapes, includingrectangular, hourglass, or any other shape. The bodyside liner 428 canbe suitably compliant, soft feeling, and non-irritating to the wearer'sskin and can be the same as or less hydrophilic than the absorbent body434 to permit body exudates to readily penetrate through to theabsorbent body 434 and provide a relatively dry surface to the wearer.

The bodyside liner 428 can be manufactured from a wide selection ofmaterials, such as synthetic fibers (for example, polyester orpolypropylene fibers), natural fibers (for example, wood or cottonfibers), a combination of natural and synthetic fibers, porous foams,reticulated foams, apertured plastic films, or the like. Examples ofsuitable materials include, but are not limited to, rayon, wood, cotton,polyester, polypropylene, polyethylene, nylon, or other heat-bondablefibers, polyolefins, such as, but not limited to, copolymers ofpolypropylene and polyethylene, linear low-density polyethylene, andaliphatic esters such as polylactic acid, finely perforated film webs,net materials, and the like, as well as combinations thereof.

Various woven and non-woven fabrics can be used for the bodyside liner428. The bodyside liner 428 can include a woven fabric, a nonwovenfabric, a polymer film, a film-fabric laminate or the like, as well ascombinations thereof. Examples of a nonwoven fabric can include spunbondfabric, meltblown fabric, coform fabric, carded web, bonded-carded web,bicomponent spunbond fabric, spunlace, or the like, as well ascombinations thereof. The bodyside liner 428 need not be a unitary layerstructure, and thus, can include more than one layer of fabrics, films,and/or webs, as well as combinations thereof. For example, the bodysideliner 428 can include a support layer and a projection layer that can behydroentangled. The projection layer can include hollow projections,such as those disclosed in U.S. Pat. No. 9,474,660 invented by Kirby,Scott S. C. et al., and as depicted in FIG. 8.

For example, the bodyside liner 428 can be composed of a meltblown orspunbond web of polyolefin fibers. Alternatively, the bodyside liner 428can be a bonded-carded web composed of natural and/or synthetic fibers.The bodyside liner 428 can be composed of a substantially hydrophobicmaterial, and the hydrophobic material can, optionally, be treated witha surfactant or otherwise processed to impart a desired level ofwettability and hydrophilicity. The surfactant can be applied by anyconventional means, such as spraying, printing, brush coating or thelike. The surfactant can be applied to the entire bodyside liner 428 orit can be selectively applied to particular sections of the bodysideliner 428.

In an embodiment, a bodyside liner 428 can be constructed of a non-wovenbicomponent web. The non-woven bicomponent web can be a spunbondedbicomponent web, or a bonded-carded bicomponent web. An example of abicomponent staple fiber includes a polyethylene/polypropylenebicomponent fiber. In this particular bicomponent fiber, thepolypropylene forms the core and the polyethylene forms the sheath ofthe fiber. Fibers having other orientations, such as multi-lobe,side-by-side, end-to-end may be used without departing from the scope ofthis disclosure. In an embodiment, a bodyside liner 428 can be aspunbond substrate with a basis weight from about 10 or 12 to about 15or 20 gsm. In an embodiment, a bodyside liner 428 can be a 12 gsmspunbond-meltblown-spunbond substrate having 10% meltblown contentapplied between the two spunbond layers.

Although the outer cover 426 and bodyside liner 428 can includeelastomeric materials, it is contemplated that the outer cover 426 andthe bodyside liner 428 can be composed of materials which are generallynon-elastomeric. In an embodiment, the bodyside liner 428 can bestretchable, and more suitably elastic. In an embodiment, the bodysideliner 428 can be suitably stretchable and more suitably elastic in atleast the lateral or circumferential direction of the absorbent article410. In other aspects, the bodyside liner 428 can be stretchable, andmore suitably elastic, in both the lateral and the longitudinaldirections 432, 430, respectively.

In the exemplary embodiment depicted in FIGS. 9-11B, the hydroentanglednonwoven material 10 described above can be used for the bodyside liner428. As illustrated in FIG. 11A, the nonwoven material 10 of the presentdisclosure can be oriented such that the plurality of nodes 12 extendfrom the base plane 18 on the first surface 20 towards the absorbentbody 434. In other words, the second surface 22 of the nonwoven material10 can form at least a portion of the body facing surface 419 of thechassis 411 configured to be against a wearer's skin. The apertured zone16 of the nonwoven material 10 can be configured to allow exudates toflow through the plurality of openings 24 in the nonwoven material 10 tolower-laying structures of the absorbent assembly 444, such as the fluidacquisition layer 448, the fluid transfer layer 446 and the absorbentbody 434.

By having nonwoven material 10 configured such that the nodes 12 extendtoward the absorbent body 434, the nodes 12 can help provide additionalvoid volume for exudates to be contained while they are being acquiredand transferred to and throughout the absorbent assembly 444, yet remainaway from the body facing surface 419 of the chassis 411 of theabsorbent article 410. In such an orientation, the nonwoven material 10can create void volume for exudates between the nonwoven material 10 andany lower structures in the absorbent article 10 due to nodes 12 of thenonwoven material 10 creating space between the base plane 18 of thefirst surface 20 and any such lower structure. The void volume forexudates created by the nonwoven material 10 can vary based on theheight of the nodes 12, the node 12 density, and the area of theapertured zone 16 of the nonwoven material 10 and can be designed toadequately suit various step sizes of absorbent articles 410 andabsorbent articles 410 designed for handling different exudates. Bycreating void volume of this nature, the nonwoven material 10 can intakeexudates with minimal spreading of exudates on the body facing surface419 of the chassis 411 of the absorbent article 410. In doing so, thenonwoven material 10 can help reduce the area of contact of exudatesagainst a wearer's skin, reducing potential for irritation of a wearer'sskin.

FIG. 11A depicts the nonwoven material 10 forming a bodyside liner 428for the absorbent article 410. In such a configuration, the nonwovenmaterial 10 can have a width that is substantially similar to a width ofthe outer cover 426. The second surface 22 of the nonwoven material 10can form a body-facing surface 419 for the absorbent article 410 and canbe configured to contact a wearer's skin.

FIG. 11B provides an alternative embodiment of an absorbent article 510,similar to the absorbent article 410 described in FIG. 11A unlessotherwise noted herein. In FIG. 11B, the absorbent article 510 caninclude a nonwoven material 10 coupled to a carrier material 151 to formthe bodyside liner 528. The carrier material 151 can be combined withthe nonwoven material 10, for example, in process 100′ described abovewith respect to FIG. 7C. The carrier material 151 can be coupled to thefirst side 20 of the nonwoven material 10. The carrier material 151 canbe disposed between the nonwoven material and the absorbent body 434. Inthe embodiment shown in FIG. 11B, the carrier material 151 can bedisposed between the nonwoven material 10 and the fluid acquisitionmaterial 448.

Other orientations and variations of the nonwoven material 10 within anabsorbent article are also within the scope of this disclosure. Forexample, while the nonwoven material 10 is shown in FIGS. 11A and 11B asbeing oriented with the nodes 12 extending from the base plane 18 of thefirst surface 20 toward the absorbent body 434, it is also contemplatedthat the nonwoven material 10 can be oriented such that the nodes 12extend from the base plane 18 of the first surface 20 away from theabsorbent body 434, such as illustrated in FIG. 11C. In the embodimentof the absorbent article 610 depicted in FIG. 11C, the nonwoven material10 can form the bodyside liner 628 with the first surface 20 providing abody facing surface 419 configured to be against a wearer's skin. Insuch an embodiment, the nodes 12 can provide separation from bodyexudates that may be on the base plane 18 of the first surface 20 of thenonwoven material 10. Additionally, the nodes 12 can provide barriers tothe spreading of body exudates, such as BM, on the first surface 20 ofthe nonwoven material 10. By reducing the spreading of exudates on thenonwoven material 10, the nonwoven material 10 can help reduceirritation of a wearer's skin and can help reduce the likelihood ofexudates leaking from the absorbent article 610.

FIG. 12 depicts an absorbent article 710, similar to absorbent articles410, 510, and 610. In the embodiment of FIG. 12, the article 710 mayinclude a nonwoven material according to the present disclosure, such asmaterial 10. As can be seen more clearly in FIG. 14, which depicts across-section of the article 710 as viewed along line 14F-14F of FIG.12, the nonwoven material 10 may be disposed on top of bodyside liner728. In some exemplary embodiments, the bodyside liner 728 may be amaterial such as the carrier material 151 described with respect toprocess 100′″ of FIG. 7C.

In the embodiment of FIG. 12, the material 10 may have a width (width 35described in FIG. 1) that is generally less than the width of thebodyside liner 728. In such embodiments, the material 10 may bepositioned on the chassis 719 of the article 710 so as to be disposedgenerally above the absorbent body 434. In some embodiments, theapertured zone 16 of the material 10 may entirely cover the absorbentbody 434. In such embodiments, the side zones 26 a, 26 b may be disposedcompletely outboard of the absorbent body 434. However, in otherembodiments, the side zones 26 a, 26 b can at least partially overlapthe absorbent body 434.

The material 10 may be bonded to the chassis 719 at least throughout afront waist bonding region 173 and throughout a rear waist bondingregion 171. The front waist bonding region 173 my generally be disposedproximate the front edge 25 of the material 10. The front waist bondingregion 173 also extends throughout the apertured zone 16 of the material10 and may extend at least partially through the side zones 26 and/or 26b in some embodiments, such as shown in FIG. 12. The front waist bondingregion 173 may have a length 186 that is greater than about 20% of anoverall length of the material 10, or is greater than about 30%, or isgreater than about 35%, or greater than about 40%, or greater than about45%, or greater than about 50% of the overall length of the material 10.In some preferred embodiments, the length 186 may be less than about60%, or less than about 55%, or less than about 50%, of the overalllength of the material 10. In at least some embodiments, the front waistbonding region 173 may be generally formed by mechanical bonding means,for example by heat bonding, ultrasonic bonding, pressure bonding, orthe like. However, in other embodiments, the front waist bonding region173 may be formed by adhesive bonding.

The large area that the front waist bonding region 173 covers may beespecially preferable where the average areas of the openings 24 of thematerial 10 within the apertured zone 16 are greater than about 17 mm²,or more preferably where the average areas are greater than about 20mm². With such large average areas of the openings 24, a risk of penilestrangulation increases for male wearers of an article 710 includingsuch a material 10. By bonding a large portion of a front region of thematerial 10 to the chassis 719, the openings 24 in the front portion ofthe article 710 are prevented from becoming wrapped around a penis of amale wearer.

The rear waist bonding region 171 is disposed proximate the rear edge 27of the material 10 and bonds the material 10 to the chassis 719. Likethe front waist bonding region 173, the rear waist bonding region 171may extend throughout the apertured zone 16 of the material 10 and mayfurther extend at least partially through the side zones 26 and/or 26 bin some embodiments. The rear waist bonding region 171 may be generallyformed by mechanical bonding means, for example by heat bonding,ultrasonic bonding, pressure bonding, or the like. Although, in otherembodiments, the rear waist bonding region 171 may be formed by adhesivebonding.

The rear waist bonding region 171 contrasts with the front waist bondingregion 173 as the rear waist bonding region 171 has a length 188 that ismuch smaller than the length 186 of the front waist bonding region 173.In the rear portion of the article 719, it is desired that the material10 is generally un-adhered to the chassis 719 so that the material 10may provide a void volume, by way of the nodes 12 facing the chassis719, to provide enhanced intake and storage qualities for fecal matterwhich is generally exuded into a rear region of the article 719proximate the rear edge 27 of the material 10. Accordingly, the length188 is preferably less than about 10% of the overall length of thematerial 10, or more preferably less than about 7.5%, or less than about5%, or less than about 2.5% of the overall length of the material 10. Insome preferred embodiments, the length 188 is preferably greater thanabout 2% of the overall length of the material 10. The rear waistbonding region 171 generally operates to ensure that the rear edge 27 ofthe material 10 is adhered to the chassis 719.

FIG. 13 depicts the material 10 in isolation from the article 710 andfurther illustrates an exemplary bonding configuration which may be usedto bond the material 10 to the chassis 719 of the absorbent article 710.As shown in FIG. 13, in addition to the boning regions 171, 173 (bothregions 171 and 173 are shown in FIG. 13 without shading to more clearlyillustrate other features within FIG. 13), the material 10 may befurther bonded to the bodyside liner 728 within the side zones 26 a, 26b by adhesive bonds 175 a, 175 b.

In some manufacturing processes of forming the article 710 including thematerial 10, adhesive may be applied to the bodyside liner 728 beforethe material 10 is brought to the liner 728 to form the bonds 175 a,175. Accordingly, in such embodiments it may be important for theadhesive bonds 175 a, 175 b to have widths 177 which are generallysmaller than the widths 31 a, 31 b of the side zones 26 a, 26 b of thematerial 10. According to some embodiments, the widths 177 may bebetween about 50% and about 90%, or between about 60% and about 80% ofthe widths 31 a, 31 b of the side zones 26 a, 26 b. Although shown asextending for the full length of the material 10, the adhesive bonds 175a, 175 b can extend for only between about 80% and about 97.5%, orbetween about 85% and about 95% of the overall length of the material10.

The width 177 being smaller than the widths 31 a, 31 b allows for someinaccuracy in a desired placement of the material 10 as it is brought tobond with the liner 728 with respect to the alignment of the side zones26 a, 26 b and the adhesive applied to the liner 728 which forms thebonds 175 a, 175 b. If the widths 177 are too great, normal processvariations can cause a large enough misalignment of the material 10 withrespect to the liner 728 to cause the adhesive used to form the bonds175 a, 175 b applied to the liner 728 to overlap with the apertured zone16 of the material 10 or be uncovered by the side zones 26 a and/or 26 bof the material 10. Such an overlap or uncovered exposure of thisadhesive can result in the adhesive being exposed, through the openings24 or otherwise, which can further result in such adhesive undesirablybonding to portions of the article 710 other than the material 10.

It is also important to balance the adhesive add-on amount of theadhesive forming the bonds 175 a, 175 b to ensure adequate laminationstrength between the material 10 and the liner 728 but also not haveadhesive bleed-through due to the relatively open nature of the sidezones 26 a, 26 b. It has been found that adhesive add-on amounts used toform the adhesive bonds 175 a, 175 b should be greater than about 6.0gsm, or greater than about 6.5 gsm, and less than about 13 gsm, or lessthan about 12 gsm. These ranges of adhesive add-on amounts have beenfound to ensure sufficient lamination strength between the material 10and the liner 728 such that the material 10 does not delaminate from theliner 728 during manufacture or in use and that adhesive bleed-throughdoes not occur in the side zones 26 a, 26 b.

In some particular embodiments, the material 10 may be coupled to theliner 728 at least through adhesive bonds 175 a, 175 b before the frontand/or rear waist bonding regions 173, 171 are formed. For example, thematerial 10 may be adhesively bonded to the liner 728 by bonds 175 a,175 b prior to the laminate of materials 10 and 728 being bondedtogether throughout bonding regions 171, 173. This may be the case wherethe bonding regions 171, 173 are formed by mechanical bonds.

In at least some of these embodiments, one or more additional bonds mayneed to be formed prior to the bonding regions 171, 173 being formed. Asone example, where the material 10 is bonded to the liner 728 in ahigh-speed manufacturing process through bonds 175 a, 175 b prior to thebonding regions 171, 173 being formed, a leading edge 25 or 27 of thematerial 10 in the process direction may undesirably fold backward priorto the bonding regions 171, 173 being formed.

For these reasons, some contemplated bonding configurations which couplethe material 10 to the liner 728 include at least one additional bond179 or 181. In some embodiments, only one of bond 179 or 181 may beformed, depending on which end 25 or 27 of the material 10 is theleading end in a process direction. In other embodiments, both bonds 179and 181 may be formed. According to some embodiments, the bonds 179and/or 181 may be formed along with the adhesive bonds 175 a, 175 b, orat least prior to the forming of the bonding regions 171 and/or 173.Such additional bonds 179 and/or 181 help to ensure that the leadingedge 25 or 27 of the material 10 is flat against the liner 728 as thebonding regions 171, 173 are formed, or both the rear edge and the frontedge 25 and 27 in the process direction where both bonds 179 and 181 areformed.

In some embodiments, the additional bond or bonds 179 and/or 181 may beadhesive bonds. According to some embodiments, the bonds 179 and/or 181may at least partially overlap the respective front waist or rear waistbonding regions 173, 171. In further embodiments, the bonds 179 and/or181 may completely overlap the front waist and/or rear waist bondingregions 173, 171.

Where the bonds 179 and/or 181 are present, the bonds 179 and/or 181 mayhave front and rear edges 190, 192 and 194, 196, respectively. The bonds179 and/or 181 may also have lengths 193 and 191, respectively. Ingeneral, the bond 179 or 181 may primarily operate to tack the leadingedge 25 or 27 in the process direction to the liner 728 to allow for thebonding region 171 of 173 to be successfully formed. Although where bothbonds 179 and 181 are present, the bonds 179, 181 may operate to tackboth the leading and trailing edges of the material 10 in the processdirection, e.g. edges 25 and 27, to the liner 27 prior to the bondingregions 171, 173 being formed. Accordingly, the lengths 191, 193 can berelatively short. According to some embodiments, the lengths 191 and/or193 may be between about 1.0 mm and about 5.0 mm, or between about 2.0mm and about 5.0 mm, or between about 3.0 mm and about 5.0 mm. Suchrelatively short lengths 191 and/or 193 may be particularly beneficialwhere the bonds 179 and/or 181 are adhesive bonds.

Where the bonds 179 and/or 181 are adhesive bonds, the rear and/or frontedges 192, 194 of the bonds 179, 181, respectively, may be positioneddistances 182, 184, respectively, from the rear edge 27 and the frontedge 25 of the material 10, as shown in FIG. 13. Although it may bedesirable for the distances 182 and/or 184 to be as small as possible,the distances 182 and/or 184 may generally be between about 2.0 mm andabout 5.0 mm, or between about 2.5 mm and about 5.0 mm, or between about2.5 mm and about 4.0 mm. Where the bonds 179 and/or 181 are adhesivebonds, such offsets from the rear and front edges 27, 25 of the material10 helps to ensure that normal alignment variations within a high-speedabsorbent article manufacturing process do not result in the adhesiveforming the bonds 179 and/or 181 becoming undesirably exposed beyond theedges 25 and/or 27 of the material 10.

As shown in FIG. 13, the bonds 179, 181 extend through the aperturedzone 16 of the material 10. Where the bonds 179, 181 are adhesive bonds,it is important for the add-on amounts of the adhesive to be relativelylow in order to prevent adhesive from bleeding through the openings 24of the apertured zone 16. Such adhesive bleed-through can causeundesired bonding between portions of the article 710. It has been foundthat the adhesive add-on amount for the adhesive bonds 179 and/or 181should be between about 10 gsm and about 40 gsm, or between about 10 gsmand about 35 gsm, or between about 15 gsm and about 35 gsm.

Although, in embodiments where both the bonds 179, 181 are formed, thebond 179 or 181 which bonds the leading edge 25 or 27 of the material 10in the manufacturing process to the liner 728 may have a higher add-onamount than the other of the bonds 179, 181. For instance, the leadingedge 25 or 27 of the material 10 is subjected to higher forces in a highspeed manufacturing process than the trailing edge 25 or 27.Accordingly, the bond 179, 181 which bonds the leading edge 25 or 27 tothe liner 728 may need to be relatively stronger than the bond 179, 181which bonds the trailing edge 25 or 27 to the liner 728. In theseembodiments, the bond 179 or 181 which bonds the leading edge 25 or 27to the liner 728 may have an add-on amount of between about 15 gsm andabout 40 gsm, or between about 25 gsm about 35 gsm. In contrast, theother of the bonds 179, 181 which bod the trialing edge 25 or 27 of thematerial 10 to the liner 728 may have an add-on amount that is greaterthan about 5 gsm but less than about 15 gsm.

Other contemplated bonding configurations may include a configurationcomprising bonds 173, 175 a, and 175 b along with just bonding region173 or with just bond 179. Further contemplated bonding configurationsmay include a configuration comprising bonds 175 a and 175 b along withbonding region 173 and just bond 181. Still further contemplated bondingconfigurations may include a configuration comprising bonds 175 a and175 b along with both bonds 179 and 181, but without bonding regions171, 173.

Waist Containment Member:

In an embodiment, the absorbent article 410 can have one or more waistcontainment members 454. FIGS. 9 and 10 illustrate a preferredembodiment of a waist containment member 454 on an absorbent article410, such as a diaper where the waist containment member 454 can bedisposed in the rear waist region 414. In some embodiments, the waistcontainment member 454 can be disposed in the front waist region 412.The waist containment member 454 can be disposed on the body facingsurface 419 of the chassis 411. The waist containment member 454 can becoupled to the chassis 411 such that a portion of the waist containmentmember 454 is free to move with respect to the chassis 411 and can forma pocket to help contain body exudates.

The waist containment member 454 can be comprised of a variety ofmaterials. In a preferred embodiment, the waist containment member 454can be comprised of a spunbond-meltblown-spunbond (“SMS”) material.However it is contemplated that the waist containment member 54 can becomprised of other materials including, but not limited to, aspunbond-film-spunbond (“SFS”), a bonded carded web (“BCW”), or anynon-woven material. In some embodiments, the waist containment member454 can be comprised of a laminate of more than one of these exemplarymaterials, or other materials. In some embodiments, the waistcontainment member 454 can be comprised of a liquid impermeablematerial. In some embodiments, the waist containment member 454 can becomprised of a material coated with a hydrophobic coating. In someembodiments, the waist containment member 54 can include an elasticmaterial to provide additional fit and containment properties to theabsorbent article 10. In such an embodiment, suitable elastic materialscan include, but are not limited to, sheets, strands or ribbons ofnatural rubber, synthetic rubber, or thermoplastic elastomeric polymers.The elastic materials can be stretched and bonded to a substrate, bondedto a gathered substrate, or bonded to a substrate and then elasticizedor shrunk, for example, with the application of heat, such that elasticretractive forces are imparted to the substrate. It is to be understood,however, that the waist containment member 454 may be omitted from theabsorbent article 410 without departing from the scope of thisdisclosure.

Fastening System:

In an embodiment, the absorbent article 410 can include a fasteningsystem. The fastening system can include one or more back fasteners 491and one or more front fasteners 492. The embodiments shown in FIGS. 9and 10 depict an embodiment with one front fastener 492. Portions of thefastening system may be included in the front waist region 412, rearwaist region 414, or both.

The fastening system can be configured to secure the absorbent article410 about the waist of the wearer in a fastened condition as shown inFIG. 9 and help maintain the absorbent article 410 in place during use.In an embodiment, the back fasteners 491 can include one or morematerials bonded together to form a composite ear as is known in theart. For example, the composite fastener may be composed of a stretchcomponent 494, a nonwoven carrier or hook base 496, and a fasteningcomponent 498, as labeled in FIG. 10.

Test Methods

Node Analysis Test Method

The anisotropy of fibers in the nodes 12 can be determined by using theimage analysis measurement method described herein. This test method canalso measure node height as well as the percentage of fibers and voidswithin a node 12.

In this context, fiber anisotropy is considered for a plurality of nodes12 from each respective material. Generally, the image analysis methoddetermines a numeric value of anisotropy from a cross-sectional image ofa node 12 via a specific image analysis measurement parameter namedanisotropy. The anisotropy of a node 12 can be measured by using x-rayMicro-computed Tomography (a.k.a. Micro-CT) to non-destructively acquireimages with subsequent image analysis techniques to detect fibercomponents and then measuring the anisotropy of said components withinthe node 12 regions only. The image analysis algorithm performsdetection, image processing and measurement and also transmits datadigitally to a spreadsheet database. The resulting measurement data areused to compare the anisotropy of differing structures possessingfibrous node 12 components.

The method for determining the anisotropy in each structures nodes'fibers includes the first step of acquiring digital x-ray Micro-CTimages of a sample. These images are acquired using a SkyScan 1272Micro-CT system available from Bruker microCT (2550 Kontich, Belgium).The sample is attached to a mounting apparatus, supplied by Bruker withthe SkyScan 1272 system, so that it will not move under its own weightduring the scanning process. The following SkyScan 1272 conditions areused during the scanning process:

Camera Pixel Size (um)=9.0 Source Voltage (kV)=35

-   -   Source Current (uA)=225 Image Pixel Size (um)=6.0 Image        Format=TIFF Depth (bits)=16 Rotation Step (deg.)=0.10    -   Use 360 Rotation=NO Frame Averaging=ON (6) Random        Movement=ON (1) Flat Field Correction=ON Filter=No Filter

After sample scanning is completed, the resulting image set is thenreconstructed using the NRecon program provided with the SkyScan 1272Micro-CT system. While reconstruction parameters can be somewhat sampledependent, and should be known to those skilled in the art, thefollowing parameters should provide a basic guideline to an analyst:

-   -   Image File Type=JPG    -   Pixel Size (urn)=6.00    -   Smoothing=1 (Gaussian)    -   Ring Artifact Correction=10    -   Beam Hardening Correction (%)=10

After reconstruction is completed, the resulting image data set is nowready for extraction of cross-sectional image slices using the BrukerSkyScan software package called DataViewer. After downloading the entirereconstructed image data set into DataViewer, the analyst, skilled inthe art of Micro-CT technologies, must then select and extractcross-sectional image slices which reside at or near the center of nodespresent in each respective sample. One centered node 12 should beobtained for each image selected. For a typical specimen, this processwill result in 4-6 images and from which 4-6 nodes 12 will be availablefor analysis. The analyst should then re-number the images sequentially(e.g. 1, 2, 3, etc.) by changing the image file suffix numbers.

Once a set of cross-sectional Micro-CT images have been acquired andre-numbered from each specimen, anisotropy measurements can now be madeusing image analysis software.

The image analysis software platform used to perform the anisotropymeasurements is a QWIN Pro (Version 3.5.1) available from LeicaMicrosystems, having an office in Heerbrugg, Switzerland.

Thus, the method for determining the anisotropy of a given sampleincludes the step of performing several anisotropy measurements on theMicro-CT image set. Specifically, an image analysis algorithm is used toread and process images as well as perform measurements using QuantimetUser Interactive Programming System (QUIPS) language. The image analysisalgorithm is reproduced below.

 DEFINE VARIABLES & OPEN FILES  The following line designates thecomputer location where data is sent to  Open File (C:\Data\94054 - Nhan(patent)\z-micro-ct data.xls, channel #1)  PauseText (“Enter the numberof the final image in the set.”)  Input (IMAGES)  SAMPLE ID AND SET UP Enter Results Header  File Results Header (channel #1)  File Line(channel #1)  Measure frame (x 31, y 61, Width 1737, Height 793)  Imageframe ( x 0, y 0, Width 1768, Height 854 ) -- Calvalue 6.0 um/pixel CALVALUE = 6.0  Calibrate (CALVALUE CALUNITS$ per pixel) -- Enter imageprefix name of set of images to analyze  PauseText ( “Enter image fileprefix name.” )  Input ( TITLE$ )  File ( “Rep. #”, channel #1 )  File (“% Fiber”, channel #1 )  File ( “% Voids”, channel #1 )  File ( “Height(um)”, channel #1 )  File ( “Anisotropy”, channel #1 )  File Line (channel #1 )  For ( REPLICATE = 1 to IMAGES, step 1 ) Clear AcceptsIMAGE ACQUISITION AND DETECTION ACQOUTPUT = 0 The following two linesindicate the computer location of the Micro-CT images to be read duringthe image analysis process. ACQFILE$ = “C:\Images\94054 -Nhan\Z-slices\”+TITLE$+“”+STR$(REPLICATE)+“.jpg” Read image ( from fileACQFILE$ into ACQOUTPUT ) Colour Transform ( Mono Mode ) Grey Transform( WSharpen from Image0 to Image1, cycles 3, operator Disc ) Detect (whiter than 64, from Image1 into Binary0 ) IMAGE PROCESSING PauseText (“Select region of interest for analysis.” ) Binary Edit [PAUSE] ( Acceptfrom Binary0 to Binary1, nib Fill, width 2 ) Binary Amend ( Close fromBinary1 to Binary2, cycles 30, operator Disc, edge erode on ) BinaryIdentify ( FillHoles from Binary2 to Binary3 ) Binary Amend ( Open fromBinary3 to Binary4, cycles 40, operator Disc, edge erode on ) PauseText( “Clean up any over extended ROI areas.” ) Binary Edit [PAUSE] ( Rejectfrom Binary4 to Binary5, nib Fill, width 2 ) PauseText ( “Draw verticallline thru the thickest region binary.” ) Binary Edit [PAUSE] ( Acceptfrom Binary5 to Binary7, nib Rect, width 2 ) Binary Logical ( C = A ANDB : C Binary6, A Binary1, B Binary5 )  MEASURE ANALYSIS REGIONS  --Analysis Region Fiber Area MFLDIMAGE = 6 Measure field ( planeMFLDIMAGE, into FLDRESULTS(2), statistics into FLDSTATS(7,2) ) Selectedparameters: Area, Anisotropy FIBERAREA = FLDRESULTS(1) ANISOTROPY =FLDRESULTS(2)  -- Analysis Region Area MFLDIMAGE = 5 Measure field (plane MFLDIMAGE, into FLDRESULTS(1), statistics into FLDSTATS(7,1) )Selected parameters: Area ROIAREA = FLDRESULTS(1) PERCFIBER =FIBERAREA/ROIAREA*100 PERCVOIDS = 100-PERCFIBER  -- Measure Node HeightMeasure feature ( plane Binary7, 8 ferets, minimum area: 24, grey image:Image0 ) Selected parameters: X FCP, Y FCP, Length LENGTH = Field Sum of( PLENGTH(FTR) ) OUTPUT DATA File ( REPLICATE, channel #1, 0 digitsafter ‘.’ ) File ( PERCFIBER, channel #1, 1 digit after ‘.’ ) File (PERCVOIDS, channel #1, 1 digit after ‘.’ ) File ( LENGTH, channel #1, 1digit after ‘.’ ) File ( ANISOTROPY, channel #1, 2 digits after ‘.’ )File Line ( channel #1 )  Next ( REPLICATE )  Close File (channel #1) END

The QUIPS algorithm is executed using the QWIN Pro software platform.The analyst is initially prompted to enter the number of images in theset for a particular specimen. Next, the analyst is prompted to enterspecimen identification information which is sent to the EXCEL file.

The analyst is next prompted by an interactive command window and aninput window to enter the image file prefix of the Micro-CT images to beanalyzed. After this step, all subsequent images for a given sample willbe read automatically by the image analysis algorithm described above.

The analyst is next prompted to manually select, with the computermouse, the node region of interest for analysis. Care should be taken toselect the entire node so as to include the tapered sections just downto base plane 18 of the material.

After several steps of image processing that will occur automatically,the analyst will again be prompted to clean up any over-extended regionof interest (ROI) areas. This is done using the computer mouse as wellas toggling the overlying binary image on and off by simultaneouslyusing the ‘control’ and ‘b’ keys on the computer keyboard. After thisstep, the binary should only be covering the node.

Lastly, the analyst will be prompted to use the computer mouse to draw avertical line thru the tallest region of the binary image. This linewill be used by the computer algorithm to measure the height of the node12.

The process of selecting the node 12 region of interest, clean up ofover-extended regions, and drawing a vertical line thru the tallestregion of the node 12 will repeat until all the images for a particularspecimen have been analyzed.

After all images have been analyzed, the following measurement parameterdata will be located in the corresponding EXCEL file:

Replicate # % Fiber % Voids Height Anisotropy

There will be 4-6 values listed in columns for each of these parameters.For the purposes of comparing anisotropy values between specimens, thedata in the column labeled ‘Anisotropy’ can be compared betweendifferent specimens by performing a Student's T analysis at the 90%confidence level.

Material Sample Analysis Test Method

The Material Sample Analysis Test Method as described herein can be usedfor determining the percent open area in a given sample nonwovenmaterial 10. In this context, the percent open area is considered as thepercent of an area of the nonwoven material in which light transmittedfrom a light source passes directly through unhindered. Generally, thisimage analysis method determines a numeric value of percent open areafor a material via specific image analysis measurement parameters suchas area. This test method and equipment also provide the ability tomeasure the size of an opening 24, the roundness of an opening 24, theaspect ratio for an opening 24, the two-dimensional area of a node 12,and node 12 density and spacing. This test method involves obtaining twoseparate digital images of the sample.

Material Apertured Zone Sample Analysis Set-up and Determination

An exemplary setup for acquiring the images of the apertured zone isrepresentatively illustrated in FIG. 15. Specifically, a CCD videocamera 70 (e.g., a Leica DFC 300 FX video camera available from LeicaMicrosystems of Heerbrugg, Switzerland) is mounted on a standard support72 such as a Polaroid MP-4 Land Camera standard support formerlyavailable from Polaroid Resource Center in Cambridge, Miss., and nowpotentially available from a resource such as eBay. The standard support72 is attached to a macro-viewer 74 such as a KREONITE macro-vieweravailable from Dunning Photo Equipment, Inc., having an office in Bixby,Okla. An auto stage 76 is placed on the upper surface of themacro-viewer 74. The auto stage 76 is used to automatically move theposition of a given sample for viewing by the camera. A suitable autostage 76 is Model H112, available from Prior Scientific Inc., having anoffice in Rockland, Mass.

The specimen (not shown in FIG. 15) is placed on the auto stage 76 of aLeica Microsystems QWIN Pro Image Analysis system, under the opticalaxis of a 60 mm lens 78 having an f-stop setting of 4, such as a NikonAF Micro Nikkor, manufactured by Nikon Corporation, having an office inTokyo, Japan. The lens 78 is attached to the camera 70 using a c-mountadaptor. The distance from the front face of the lens 78 to the sampleis approximately 55 cm. The sample is laid flat on the auto stagesurface 80 and any wrinkles removed by gentle stretching and/orfastening it to the auto stage surface 80 using transparent adhesivetape at its outer edges. The sample surface is illuminated with incidentfluorescent lighting provided by a 16 inch diameter, 40 watt, Circlinefluorescent light 82, such as that manufactured by General ElectricCompany, having an office in Boston, Mass. The light 82 is contained ina fixture that is positioned so it is centered over the sample and isapproximately 3 cm above the sample surface. The illumination level ofthe light 82 is controlled with a Variable Auto-transformer (not shown),type 3PN1010, available from Staco Energy Products Co. having an officein Dayton, Ohio Transmitted light is also provided to the sample frombeneath the auto stage by a bank of four, 2-foot, EMC, Double-EndPowered LED tube lights 84 which are dimmable and available from FulightOptoelectronic Materials, LLC. The LED lights 84 are covered with adiffusing plate 86. The diffusing plate 86 is inset into, and forms aportion of, the upper surface 88 of the macro-viewer 74. Thisillumination source is overlaid with black mask 90 possessing a 3-inchby 3-inch opening 92. The opening 92 is positioned so that it iscentered under the optical axis of the camera 70 and lens 78 system. Thedistance D3 from the fluorescent light opening 92 to the surface 80 ofthe auto stage 76 is approximately 17 cm. The illumination level of thefluorescent light bank is also controlled with a separate power controlbox (not shown) configured for dimmable LED lights.

The image analysis software platform used to perform the percent openarea and aperture size measurements is a QWIN Pro (Version 3.5.1)available from Leica Microsystems, having an office in Heerbrugg,Switzerland. Alternatively, LAS Macro Editor, the next generation ofsoftware following QWIN Pro, could be used to perform the analysis. Thesystem and images are also accurately calibrated using the QWIN softwareand a standard ruler with metric markings at least as small as onemillimeter. The calibration is performed in the horizontal dimension ofthe video camera image. Units of millimeters per pixel are used for thecalibration.

Thus, the method for determining the percent open area and opening sizeof a given specimen includes the step of performing measurements on thetransmitted light image. Specifically, an image analysis algorithm isused to acquire and process images as well as perform measurements using

Quantimet User Interactive Programming System (QUIPS) language. Theimage analysis algorithm is reproduced below. For purposes of clarity,the references in the algorithm to “bumps” or “projections” refers tonodes 12 for the nonwoven material 10 and the references to “open areas”or “apertures” refers to openings 24 for the nonwoven material 10.

DEFINE VARIABLES & OPEN FILES  The following line designates thecomputer location where data is sent to  Open File (C:\Data\94054 - Nhan(patent)\data.xls, channel #1)  TOTCOUNT = 0  TOTFIELDS = 0  MFRAMEH =875  MFRAMEW = 1249  SAMPLE ID AND SET UP  Configure ( Image Store 1392x 1040, Grey Images 81, Binaries 24 )  Enter Results Header  FileResults Header ( channel #1 )  File Line ( channel #1 )  PauseText (“Enter sample image prefix name now.” )  Input ( TITLE$ )  PauseText (“Set sample into position.” )  Image Setup DC Twain [PAUSE] ( Camera 1,AutoExposure Off, Gain 0.00, ExposureTime 34.23 msec, Brightness 0, Lamp38.83 )  Measure frame ( x 74, y 110, Width 1249, Height 875 )  Imageframe ( x 0, y 0, Width 1392, Height 1040 )  -- Calvalue = 0.0377 mm/px CALVALUE = 0.0377  Calibrate ( CALVALUE CALUNITS$ per pixel )  FRMAREA= MFRAMEH*MFRAMEW*(CALVALUE**2)  Clear Accepts  For ( SAMPLE = 1 to 1,step 1 ) Clear Accepts File ( “Field No.”, channel #1, field width: 9,left justified ) File ( “% Open Area”, channel #1, field width: 7, leftjustified ) File ( “Bump Density”, channel #1, field width: 13, leftjustified ) File ( “Bump Spacing”, channel #1, field width: 15, leftjustified ) File Line ( channel #1 ) Stage ( Define Origin ) Stage (Scan Pattern, 1 x 5 fields, size 82500.000000 x 39000.000000 ) IMAGEACQUISITION I - Projection isolation For ( FIELD = 1 to 5, step 1 )Measure frame ( x 74, y 110, Width 1249, Height 875 ) Display ( Image0(on), frames (on,on), planes (off,off,off,off,off,off), lut 0, x 0, y 0,z 1, Reduction off ) PauseText ( “Ensure incident lighting is correct(WL = 0.88 - 0.94) and acquire image.” ) Image Setup DC Twain [PAUSE] (Camera 1, AutoExposure Off, Gain 0.00, ExposureTime 34.23 msec,Brightness 0, Lamp 38.83 ) Acquire ( into Image0 ) DETECT - Projectionsonly PauseText ( “Ensure that threshold is set at least to the right ofthe left gray-level histogram peak which corresponds to the ‘land’region.” ) Detect [PAUSE] ( whiter than 129, from Image0 into Binary0delineated ) BINARY IMAGE PROCESSING Binary Amend ( Close from Binary0to Binary1, cycles 10, operator Disc, edge erode on ) Binary Identify (FillHoles from Binary1 to Binary1 ) Binary Amend ( Open from Binary1 toBinary2, cycles 20, operator Disc, edge erode on ) Binary Amend ( Closefrom Binary2 to Binary3, cycles 8, operator Disc, edge erode on )PauseText ( “Toggle <control> and <b> keys to check projection detectionand correct if necessary.” ) Binary Edit [PAUSE] ( Reject from Binary3to Binary3, nib Fill, width 2 ) Binary Logical ( copy Binary3, invertedto Binary4 ) IMAGE ACQUISITION 2 - % Open Area & Aperture Size Measureframe ( x 74, y 110, Width 1249, Height 875 ) Display ( Image0 (on),frames (on,on), planes (off,off,off,off,off,off), lut 0, x 0, y 0, z 1,Reduction off ) PauseText ( “Turn off incident light & ensuretransmitted lighting is correct (WL = 0.95) and acquire image.” ) ImageSetup DC Twain [PAUSE] ( Camera 1, AutoExposure Off, Gain 0.00,ExposureTime 34.23 msec, Brightness 0, Lamp 38.83 ) Acquire ( intoImage0 ) ACQFILE$ = “C:\Images\94054 -Nhan\”+TITLE$+“_”+STR$(FIELD)+“.jpg” Write image ( from ACQOUTPUT intofile ACQFILE$ ) DETECT - Open areas only Detect ( whiter than 127, fromImage0 into Binary10 delineated ) BINARY IMAGE PROCESSING Binary Amend (Close from Binary10 to Binary11, cycles 5, operator Disc, edge erode on) Binary Identify ( FillHoles from Binary11 to Binary12 ) Binary Amend (Open from Binary12 to Binary13, cycles 10, operator Disc, edge erode on) Binary Identify ( EdgeFeat from Binary13 to Binary14 ) PauseText (“Ensure apertures are detected accurately.” ) Binary Edit [PAUSE] (Reject from Binary14 to Binary14, nib Fill, width 2 ) FIELDMEASUREMENTS - % Open Area, Bump Density & Spacing  -- % open areaMFLDIMAGE = 10 Measure field ( plane MFLDIMAGE, into FLDRESULTS(1),statistics into FLDSTATS(7,1) ) Selected parameters: Area% FieldHistogram #1 ( Y Param Number, X Param Area %, from 0. to 60., linear,20 bins ) PERCOPENAREA = FLDRESULTS(1) -- bump density & spacingMFLDIMAGE = 3 Measure field ( plane MFLDIMAGE, into FLDRESULTS(5),statistics into FLDSTATS(7,5) ) Selected parameters: Area, Intercept H,Intercept V, Area%, Count/Area BUMPDENSITY = FLDRESULTS(5) MNSPACE1 =(FRMAREA-FLDRESULTS(1))/(FLDRESULTS(2)+FLDRESULTS(3))/2 Field Histogram#2 ( Y Param Number, X Param MNSPACE1, from 0. to 50., linear, 25 bins )File ( FIELD, channel #1, 0 digits after ‘.’ ) File ( PERCOPENAREA,channel #1, 1 digit after ‘.’ ) File ( BUMPDENSITY, channel #1, 1 digitafter ‘.’ ) File ( MNSPACE1, channel #1, 1 digit after ‘.’ ) File Line (channel #1 ) FEATURE MEASUREMENTS - Aperture and bump sizes -- Bump SizeMeasure feature ( plane Binary3, 8 ferets, minimum area: 24, grey image:Image0 ) Selected parameters: Area, X FCP, Y FCP, EquivDiam FeatureHistogram #1 ( Y Param Number, X Param Area, from 1. to 100.,logarithmic, 20 bins ) Feature Histogram #2 ( Y Param Number, X ParamEquivDiam, from 1. to 100., logarithmic, 20 bins ) -- Aperture SizeMeasure feature ( plane Binary14, 8 ferets, minimum area: 24, greyimage: Image0 ) Selected parameters: Area, X FCP, Y FCP, Roundness,AspectRatio, EquivDiam Feature Histogram #3 ( Y Param Number, X ParamArea, from 1. to 100., logarithmic, 20 bins ) Feature Histogram #4 ( YParam Number, X Param EquivDiam, from 1. to 100., logarithmic, 20 bins )Feature Histogram #5 ( Y Param Number, X Param Roundness, from0.8999999762 to 2.900000095, linear, 20 bins ) Feature Histogram #6 ( YParam Number, X Param AspectRatio, from 1. to 3., linear, 20 bins )Stage ( Step, Wait until stopped + 1100 msecs ) Next ( FIELD )  Next (SAMPLE )  File Line ( channel #1 )  File Line ( channel #1 )  OUTPUTFEATURE HISTOGRAMS  File ( “Bump Size (area - sq. mm)”, channel #1 ) File Line ( channel #1 )  File Feature Histogram Results ( #1,differential, statistics, bin details, channel #1 )  File Line ( channel#1 )  File Line ( channel #1 )  File ( “Bump Size (ECD - mm)”, channel#1 )  File Line ( channel #1 )  File Feature Histogram Results ( #2,differential, statistics, bin details, channel #1 )  File Line ( channel#1 )  File Line ( channel #1 )  File ( “Aperture Size (area - sq. mm)”,channel #1 )  File Line ( channel #1 )  File Feature Histogram Results (#3, differential, statistics, bin details, channel #1 )  File Line (channel #1 )  File Line ( channel #1 )  File ( “Aperture Size (ECD −mm)”, channel #1 )  File Line ( channel #1 )  File Feature HistogramResults ( #4, differential, statistics, bin details, channel #1 )  FileLine ( channel #1 )  File Line ( channel #1 )  File ( “ApertureRoundness”, channel #1 )  File Line ( channel #1 )  File FeatureHistogram Results ( #5, differential, statistics, bin details, channel#1 )  File Line ( channel #1 )  File Line ( channel #1 )  File (“Aperture Aspect Ratio”, channel #1 )  File Line ( channel #1 )  FileFeature Histogram Results ( #6, differential, statistics, bin details,channel #1 )  File Line ( channel #1 ) File Line ( channel #1 ) CloseFile ( channel #1 ) END

The QUIPS algorithm is executed using the QWIN Pro software platform.The analyst is initially prompted to enter the specimen set informationwhich is sent to the EXCEL file.

The analyst then enters an image file prefix name corresponding to thespecimen identification. This will be used by the algorithm to saveimages acquired during the analysis to a specified file location. Theanalyst is next prompted by a live image set up window on the computermonitor screen to place a specimen onto the auto-stage. The sampleshould be laid flat and gentle force applied at its edges to remove anymacro-wrinkles that may be present. At this time, the Circlinefluorescent light 82 can be on to assist in positioning the specimen.Next, the analyst is prompted to adjust the incident Circlinefluorescent incident light 82 via the Variable Auto-transformer to awhite level reading of approximately 0.9. The sub-stage transmittedlight should either be turned off at this time or masked using a pieceof light-blocking, black construction paper placed over the 3 inch by 3inch opening 92.

The analyst is now prompted to ensure that the detection threshold isset to the proper level for detection of the nodes 12 using theDetection window which is displayed on the computer monitor screen.Typically, the threshold is set using the white mode at a pointapproximately near the middle of the 8-bit gray-level range (e.g. 127).If necessary, the threshold level can be adjusted up or down so that theresulting detected binary will optimally encompass the nodes 12 shown inthe acquired image.

After the algorithm automatically performs several binary imageprocessing steps on the detected binary of the nodes 12, the analystwill be given an opportunity to re-check node detection and correct anyinaccuracies. The analyst can toggle both the ‘control’ and ‘b’ keyssimultaneously to re-check node detection against the underlyingacquired gray-scale image. If necessary, the analyst can select from aset of binary editing tools (e.g. draw, reject, etc.) to make any minoradjustments. If care is taken to ensure proper illumination anddetection in the previously described steps, little or no correction atthis point should be necessary.

Next, the analyst is prompted to turn off the incident Circlinefluorescent light 82 and either turn on the sub-stage transmitted lightor remove the light blocking mask. The sub-stage transmitted light isadjusted by the LED power controller to a white level reading ofapproximately 0.95. At this point, the image focus can be optimized forthe apertured zone 16 of the material 10 including openings 24.

The algorithm, after performing additional operations on the resultingseparate binary images for openings 24, will then prompt the analyst tore-check opening 24 detection against the underlying gray-scale image.If necessary, the analyst can select from a set of binary editing tools(e.g. draw, reject, etc.) to make any minor adjustments.

The algorithm will then automatically perform measurements and outputthe data into a designated EXCEL spreadsheet file.

Following the transfer of data, the algorithm will direct the auto-stageto move to the next field-of-view and the process of turning on theincident, Circline fluorescent light 82 and blocking the transmittedsub-stage lighting will begin again. This process will repeat four timesso that there will be five sets of data from five separate field-of-viewimages per single sampling replicate.

After completion of the analysis, the following measurement parameterdata will be located in the EXCEL file after measurements and datatransfer has occurred:

Percent Open Area Node Density (No. per sq. metre) Node Spacing (mm)Node Size (One histogram for area in mm² and one histogram forequivalent circular diameter in mm)

Aperture Size (One histogram for area in mm² and one histogram forequivalent circular diameter in mm)

Aperture Roundness

Aperture Aspect Ratio

The final specimen mean spread value is usually based on an N=5 analysisfrom five, separate, specimen subsample replicates. A comparison of thepercent open area, opening 24 (aperture) size and other parametersacquired by the algorithm between different specimens can be performedusing a Student's T analysis at the 90% confidence level.

Material Side Zone Percent Open Area Set-up and Determination

The setup for acquiring the images of the material side zones is similarto the set-up for acquiring images of the material apertured zone, witha few minor differences, as detailed below.

The camera and lens, the support, and the stage used to capture theimages of the material side zones, and settings for the same, are allthe same as used in the Material Apertured Zone Sample Analysis Set-upand Determination. However, in the present set-up, no macro-viewer wasused. The test material side zone sample is prepared and placed onto theauto-stage surface 80 as in the Material Apertured Zone Sample AnalysisSet-up and Determination. However, instead of illuminating the samplesurface with incident fluorescent lighting provided by a Circlinefluorescent light, light was transmitted to the sample from under thesample by a ChromaPro 45 device, formerly available from Circle S inTempe, Ariz., that had a 3-inch by 3-inch sized opening black maskoverlaid on its surface.

As with the Material Apertured Zone Sample Analysis Set-up andDetermination, the image analysis software platform used to perform thepercent open area measurement for the material side zones is the QWINPro (Version 3.5.1) available from Leica Microsystems. Alternatively,LAS Macro Editor, the next generation of software following QWIN Pro,could be used to perform the analysis. The system and images are alsoaccurately calibrated using the QWIN software and a standard ruler withmetric markings at least as small as one millimeter. The calibration isperformed in the horizontal dimension of the video camera image. Unitsof millimeters per pixel are used for the calibration.

In the Material Side Zone Percent Open Area Set-up and Determination,upon running the QWIN

Pro program, the light level was set at 0.95 using the white levelfunction in the QWIN Pro program to adjust the light output of theChromaPro light output. The QWIN Pro program was further configured tomove the Prior auto-stage so that six images were automatically acquiredand measured from each side of the sample material, resulting in twelvetotal measurements.

Thus, the method for determining the percent open area of a side zoneincludes the step of performing measurements on the transmitted lightimage. Specifically, an image analysis algorithm is used to acquire andprocess images as well as perform measurements using Quantimet UserInteractive Programming System (QUIPS) language. The image analysisalgorithm is reproduced below.

DEFINE VARIABLES & OPEN FILES The following line designates the computerlocation where data is sent to Open File ( D:\Data\103470 -Nhan\data.xls, channel #1 )  TOTCOUNT = 0  TOTFIELDS = 0  MFRAMEH = 875 MFRAMEW = 1249  SAMPLE ID AND SET UP  Configure ( Image Store 1392 x1040, Grey Images 81, Binaries 24 )  Enter Results Header  File ResultsHeader ( channel #1 )  File Line ( channel #1 )  PauseText ( “Entersample image prefix name now.” )  Input ( TITLE$ )  Measure frame ( x511, y 50, Width 446, Height 940 )  Image frame ( x 0, y 0, Width 1392,Height 1040 )  PauseText ( “Set sample into position.” )  Image Setup DCTwain [PAUSE] ( Camera 1, AutoExposure Off, Gain 0.00, ExposureTime34.23 msec, Brightness 0, Lamp 38.83 )  -- Calvalue = 0.0333 mm/px CALVALUE = 0.0333  Calibrate ( CALVALUE CALUNITS$ per pixel )  FRMAREA= MFRAMEH*MFRAMEW*(CALVALUE**2)  File ( “Field No.”, channel #1, fieldwidth: 9, left justified )  File ( “% Open Area”, channel #1, fieldwidth: 7, left justified )  File Line ( channel #1 )  For ( SAMPLE = 1to 2, step 1 ) Clear Accepts Stage ( Define Origin ) Stage ( ScanPattern, 1 x 6 fields, size 82500.000000 x 39000.000000 ) For ( FIELD =1 to FIELDS, step 1 ) IMAGE ACQUISITION ACQOUTPUT = 0 Measure frame ( x511, y 50, Width 446, Height 940 ) Display ( Image0 (on), frames(on,on), planes (off,off,off,off,off,off), lut 0, x 0, y 0, z 1,Reduction off ) PauseText ( “Turn off incident light & ensuretransmitted lighting is correct (WL = 0.95) and acquire image.” ) ImageSetup DC Twain [PAUSE] ( Camera 1, AutoExposure Off, Gain 0.00,ExposureTime 34.23 msec, Brightness 0, Lamp 38.83 ) Acquire ( intoImage0 ) ACQFILES = “D:\Images\103470 −Nhan\”+TITLE$+“_”+STR$(FIELD)+“.jpg” Write image ( from ACQOUTPUT intofile ACQFILE$ ) DETECT - Open areas only Detect ( whiter than 164, fromImage0 into Binary10 ) BINARY IMAGE PROCESSING Binary Amend ( Close fromBinary10 to Binary11, cycles 1, operator Disc, edge erode on ) BinaryIdentify ( FillHoles from Binary11 to Binary12 ) Binary Identify (EdgeFeat from Binary12 to Binary13 ) FIELD MEASUREMENTS -- % open areaMFLDIMAGE = 13 Measure field ( plane MFLDIMAGE, into FLDRESULTS(1),statistics into FLDSTATS(7,1) ) Selected parameters: Area % FieldHistogram #1 ( Y Param Number, X Param Area %, from 0. to 5., linear, 20bins ) Display Field Histogram Results ( #1, horizontal, differential,bins + graph (Y axis linear), statistics ) Data Window ( 1449, 599, 423,270 ) PERCOPENAREA = FLDRESULTS(1) File ( FIELD, channel #1, 0 digitsafter ‘.’ ) File ( PERCOPENAREA, channel #1, 1 digit after ‘.’ ) FileLine ( channel #1 ) FEATURE MEASUREMENTS -- Aperture Size Stage ( Step,Wait until stopped + 1100 msecs ) Next ( FIELD ) File Line ( channel #1) PauseText ( “Load next replicate now.” ) Image Setup DC Twain [PAUSE]( Camera 1, AutoExposure Off, Gain 0.00, ExposureTime 23.16 msec,Brightness 0, Lamp 38.83 )  Next ( SAMPLE )  File Line ( channel #1 ) OUTPUT FEATURE HISTOGRAMS  File ( “% Area Histogram”, channel #1 ) File Line ( channel #1 )  File Line ( channel #1  File Field HistogramResults ( #1, differential, statistics, bin details, channel #1 )  CloseFile ( channel #1 ) END

In the Material Side Zone Percent Open Area Set-up and Determination,the QUIPS algorithm is executed using the QWIN Pro software platform.The analyst is initially prompted to enter the specimen set informationwhich is sent to the EXCEL file.

The analyst then enters an image file prefix name corresponding to thespecimen identification. This will be used by the algorithm to saveimages acquired during the analysis to a specified file location. Theanalyst is next prompted by a live image set up window on the computermonitor screen to place a specimen onto the auto-stage. The sampleshould be laid flat and gentle force applied at its edges to remove anymacro-wrinkles that may be present. At this point, the light levelshould be set at 0.95 using the white level function in the QWIN Proprogram to adjust the light output of the ChromaPro light output, if notalready done so. At this point, the image focus can be optimized for theside zone 26 a, or 26 b of the material 10 including micro-apertures 81and/or regions of greatly reduced fiber density 39.

The algorithm, after performing additional operations on the resultingseparate binary images for micro-apertures 81 and/or regions of greatlyreduced fiber density 39, will then prompt the analyst to re-checkdetection of the micro-apertures 81 and/or regions of greatly reducedfiber density 39 against the underlying gray-scale image. If necessary,the analyst can select from a set of binary editing tools (e.g. draw,reject, etc.) to make any minor adjustments.

The algorithm will then automatically perform measurements and outputthe data into a designated EXCEL spreadsheet file.

Following the transfer of data, the algorithm will direct the auto-stageto move to the next field-of-view. This process will repeat six timesalong each edge of the material side zone sample so that there will betwelve sets of data from twelve separate field-of-view images per singlesampling replicate.

After completion of the analysis, the following measurement parameterdata will be located in the EXCEL file after measurements and datatransfer has occurred:

Percent Open Area

The final specimen mean spread value is usually based on an N=5 analysisfrom five, separate, specimen subsample replicates. A comparison of thepercent open area acquired by the algorithm between different specimenscan be performed using a Student's T analysis at the 90% confidencelevel.

Compression Energy Test

The Compression Energy test utilized herein is a three-cycle compressiontest can be performed to measure the compression resiliency ofprojections on single layer projection layer.

Compression resiliency is measured by measuring compression energy.Generally, compression energy refers to the energy required to compressthe projection layer from its initial thickness at 5 grams force (about0.027 kPa) down to its final thickness at about 1830 grams force (about10 kPa). Compression energy is calculated as the area under thecompression stress (force/area) versus linear thickness curve define byinitial contact pressure (5 grams force) and finial contact pressure atabout 1830 grams force (about 10 kPa).

1. If the nonwoven material desired to be tested forms part of acomposite or absorbent article, use “freeze off” spray to carefullyremove the nonwoven material.2. From the nonwoven material, cut a circular test sample using a 47.8mm diameter cutting die.3. The upper and lower platens made of stainless steel are attached to atensile tester.4. The top platen has a diameter of 89 mm while the lower platen has adiameter of 152 mm. The upper platen is connected to a 100 N load cellwhile the lower platen is attached to the base of the tensile tester.5. TestWorks Version 4 software program provided by MTS is used tocontrol the movement of the upper platen and record the load and thedistance between the two platens.6. The upper platen is activated to slowly move downward and touch thelower platen until the compression load reaches around 5000 g. At thispoint, the distance between the two platens is zero.7. The upper platen is then set to move upward (away from the lowerplaten) until the distance between the two platens reaches 15 mm.8. The crosshead reading shown on TestWorks Version 4 software programis set to zero.9. A test sample is placed on the center of the lower platen with thenodes facing toward the upper platen.10. The upper platen is activated to descend toward the lower platen andcompress the test sample at a speed of 10 mm/min. The distance that theupper platen travels is indicated by the crosshead reading. This is aloading process.11. The compression should continue until the load exceeds 1830 gramsforce (about 10 kPa), at which point the platen should reverse directionand travel up at a rate of 10 mm/minute until the force decreases below5 grams force. The platen should then reverse direction and be in asecond compression cycle at a rate of 10 mm/minute until a load of 1830grams force (about 10 kPa) is exceeded. Once the load exceeds 1830 gramsforce (about 10 kPa), at which points the platen should reversedirection and travel up at a rate of 10 mm/minute until the forcedecreases below 5 grams force. The platen should then reverse directionagain and be in a third compression cycle at a rate of 10 mm/minuteuntil a load of 1830 grams force (about 10 kPa) is exceeded. At thatpoint, the upper platen stops moving downward and returns at a speed of10 mm/min to its initial position where the distance between the twoplatens is 15 mm.12. The compression load and the corresponding distance between the twoplatens during the loading and unloading are recorded on a computerusing TestWorks Version 4 software program provided by MTS.13. The compression load is converted to the compression stress bydividing the compression force by the area of the test sample, which is17.94 cm².14. The distance between the two platens at a given compression stressrepresents the thickness under that particular compression stress.15. A total of six test samples are tested for each test sample code toget representative loading and unloading curves for each test samplecode.

Compression Linearity Test

Compression Linearity is measured using the Kawabata Evaluation SystemKES model FB-3, again available from Kato Tech Company.

The instrument is designed to measure the compression properties ofmaterials by compressing the sample between two plungers. To measure thecompression properties, the top plunger is brought down on the sample ata constant rate until it reaches the maximum preset force. Thedisplacement of the plunger is detected by a potentiometer. The amountof pressure taken to compress the sample (P, gf/cm2) vs. thickness(displacement) of the material (T, mm) is plotted on the computerscreen. For all the materials in this study, the following instrumentsettings were used:

Sensitivity=2×5

Gear (speed)=1 mm/50 secFm set=5.0Stroke select=Max 5 mmCompression area=2 cm²Time lag=standardMax compression force=50 gfThe KES algorithm calculates the following compression characteristicvalues and displays them on a computer screen:

Compression Linearity (LC).

5 measurements were taken on each sample.

Tensile Strength Test Method

The Tensile Strength Test Method utilized herein is performed to measurethe compression tensile strength of each of the side zones 26 a, 26 band the apertured region of the materials of the present disclosure. Thetensile strengths are generally reported as a lbs force value (gramsforce) at a given strain.

1. If the nonwoven material desired to be tested forms part of acomposite or absorbent article, “freeze off” spray should be used tocarefully remove the nonwoven material.2. From the nonwoven material, the side zones are cut from the aperturedzone using a paper cutter along the machine direction. There should beabout 1 mm of the side zone left on each side of the apertured zoneafter cutting. The three pieces (side Zone 1, side Zone 2, and aperturedzone) are tested separately on a tensile frame.3. The upper and lower grips should be wider than width of a testsamples. The upper grip is connected to a 100 N load cell while thelower grip is attached to the base of the tensile tester.4. TestWorks Version 4 software program provided by MTS is used tocontrol the movement of the upper grip and record the load and thedistance between the two grips. Test setting are:

Gauge length=76.2 mm

Crosshead speed=305 mm/min

Slack Pre-load=25 grams force

5. A test sample with the longitudinal direction oriented vertically isplaced on the center of the lower grips6. The upper grip is activated to pull upward at a speed of 305 mm/min.The distance that the upper grip travels is indicated by the crossheadreading.7. The tensile load and the corresponding distance the upper griptravels during the test are recorded on a computer using TestWorksVersion 4 software program provided by MTS.8. The travel distance of the upper grip is converted to percent strainby dividing the travel distance by the gauge length and multiply by 100.

Once the data has been recorded, a Tensile Strength Ratio parameter canbe calculated. The Tensile Strength Ratio is determined in the followingmanner. With the results of the Tensile Strength Test Method, for eachof the side zones 1 and 2 and the apertured zone 16, a strain common toeach of the side zone 1, side zone 2, and the apertured zone samples isfound at which the total load (load of side zone 1 at the commonstrain+load of side zone 2 at the common strain+load of the aperturedzone at the common strain) is equal to 1.2 pound force (544.3 gramsforce). Where there is no common strain for which the combined load isequal to 1.2 lbs force, a common strain for which the combined load isas close to 1.2 lbs force as possible is chosen. However, the combinedload should still be within +/−10% of 1.2 lbs force. Once this commonstrain value has been found, the Tensile Strength Ratio parameter may bedetermined according to the below equation (1).

Ratio=(load of side zone 1 at the common strain+load of side zone 2 atthe common strain)/(load of apertured zone at the common strain)  (1)

Poisson's Ratio Test Method

The Possion's Ratio Test Method can be used to determine an amount ofnecking a material may experience when placed under longitudinaltension. More specifically, Poisson's ratio is a measure of thetransverse strain of a material divided by the longitudinal strain.Poisson's ratios herein are reported as a ratio at a given longitudinalstrain.

The steps of the Poisson's Ratio Test Method begin the same as the steps1-5 of the Tensile Strength Test Method, with the sample being theapertured zone of the sample material. The following steps are specificto the Poisson's Ratio Test Method:

6. The width of the sample apertured zone material is marked atmid-point of the sample material between the upper and lower grips witha felt-tipped marker or other marking device, and the width of thesample material is measured along the marked section and recorded.7. The upper grip is activated to pull upward at a speed of 305 mm/minuntil 1% longitudinal strain of the sample material is achieved. Once 1%longitudinal strain is achieved, the upper grip is stopped.8. The width of the sample material is measured along the marked sectionand recorded.9. The steps 7 and 8 are repeated for 2%, 3%, 4%, and 5% longitudinalstrain.10. Transverse strain values for the sample material are calculated ateach of the achieved longitudinal strains.11. The Poisson's ratio is then determined for the sample material ateach recorded longitudinal strain by dividing the determined transversestrain values by their associated longitudinal strain value.

Ligament Anisotropy Test Method

The anisotropy of fibers in the connecting ligaments 14 extendingbetween longitudinally adjacent nodes 12 and the connecting ligaments 14extending between laterally adjacent nodes 12 can be determined by usingthe image analysis measurement method described herein.

In this context, fiber anisotropy is considered for a pluralityconnecting ligaments 14 within an apertured zone 16 of a material, foreach respective material. Generally, the image analysis methoddetermines a numeric value of anisotropy from approximately eightcross-sectional (coronal) images of a connecting ligament 14 via aspecific image analysis measurement parameter named anisotropy. Theanisotropy of a connecting ligament 14 can be measured by using x-rayMicro-computed Tomography (a.k.a. Micro-CT) to non-destructively acquireimages with subsequent image analysis techniques to detect fibercomponents and then measuring the anisotropy of said components withinthe connecting ligament 14 regions only. The image analysis algorithmperforms detection, image processing and measurement and also transmitsdata digitally to a spreadsheet database. The resulting measurement dataare used to compare the anisotropy of connecting ligaments 14 extendingbetween longitudinally adjacent nodes 12 and connecting ligaments 14extending between laterally adjacent nodes 12.

The method for determining the anisotropy in each connecting ligaments'fibers includes the first step of acquiring digital x-ray Micro-CTimages of a sample. These images are acquired using a SkyScan 1272Micro-CT system available from Bruker microCT (2550 Kontich, Belgium).The sample is attached to a mounting apparatus, supplied by Bruker withthe SkyScan 1272 system, so that it will not move under its own weightduring the scanning process. The following SkyScan 1272 conditions areused during the scanning process:

Camera Pixel Size (um)=9.0

-   -   Source Voltage (kV)=35    -   Source Current (uA)=225    -   Image Pixel Size (um)=6.0    -   Image Format=TIFF    -   Depth (bits)=16    -   Rotation Step (deg.)=0.10    -   Use 360 Rotation=NO    -   Frame Averaging=ON (6)    -   Random Movement=ON (1)    -   Flat Field Correction=ON    -   Filter=No Filter

After sample scanning is completed, the resulting image set is thenreconstructed using the NRecon program provided with the SkyScan 1272Micro-CT system. While reconstruction parameters can be somewhat sampledependent, and should be known to those skilled in the art, thefollowing parameters should provide a basic guideline to an analyst:

-   -   Image File Type=JPG    -   Pixel Size (um)=6.00    -   Smoothing=1 (Gaussian)    -   Ring Artifact Correction=10    -   Beam Hardening Correction (%)=10

After reconstruction is completed, the resulting image data set is nowready for extraction of cross-sectional image slices using the BrukerSkyScan software package called DataViewer (v. 1.5.6.3). Afterdownloading the entire reconstructed image data set into DataViewer, theanalyst, skilled in the art of Micro-CT technologies, must then selectand extract cross-sectional (coronal) image slices at eight differentlocations along each examined connecting ligament 14. In a typicalprocess, six different connecting ligaments 14 of each type (e.g.connecting ligaments 14 extending between longitudinally adjacent nodes12 and connecting ligaments 14 extending between laterally adjacentnodes 12) are analyzed. Once a set of cross-sectional Micro-CT imageshave been acquired for each desired connecting ligament 14, anisotropymeasurements can now be made using image analysis software.

The image analysis software platform used to perform the anisotropymeasurements is a QWIN Pro (Version 3.5.1) available from LeicaMicrosystems, having an office in Heerbrugg, Switzerland.

Thus, the method for determining the anisotropy of a given sampleincludes the step of performing several anisotropy measurements on theMicro-CT image set. Specifically, an image analysis algorithm is used toread and process images as well as perform measurements using QuantimetUser Interactive Programming System (QUIPS) language. The image analysisalgorithm is reproduced below.

 OPEN DATA FILES & SET VARIABLES The following line designates thecomputer location where data is sent to  Open File ( C:\Data\103470 -Nhan\data.xls, channel #1 )  ACQOUTPUT = 0  SET-UP AND CALIBRATION Configure ( Image Store 1504 x 1250, Grey Images 102, Binaries 32 )  --Pixel calibration value = 6.00 um/px  CALVALUE = 6.00  Calibration (Local )  Image frame ( x 0, y 0, Width 1504, Height 1250 )  Measureframe ( x 31, y 61, Width 1442, Height 1188 )  Enter Results Header File Results Header ( channel #1 )  File Line ( channel #1 )  File Line( channel #1 )  -- Enter image file information  PauseText ( “Enterimage file prefix name.” )  Input ( TITLE$ )  Clear Feature Histogram #1 Clear Feature Histogram #2  Clear Field Histogram #1  FIELD/ANALYSISLOOP  For ( FIELD = 440 to 480, step 5 ) IMAGE ACQUISITION & DETECTION-- Image File location ACQFILE$ = “C:\Images\103470 − Nhan\CoronalImages\Rep #3\”+TITLE$+“”+STR$(FIELD)+“.jpg” Read image ( from fileACQFILE$ into ACQOUTPUT ) DETECTION OF FIBERS Clear Feature Histogram #1Clear Feature Histogram #2 Detect ( whiter than 55, from Image0 intoBinary0 delineated ) IMAGE PROCESSING Binary Amend ( Close from Binary0to Binary1, cycles 1, operator Disc, edge erode on ) Binary Amend (White Exh. Skeleton from Binary1 to Binary2, cycles 1, operator Disc,edge erode on, alg. ‘L’ Type ) Binary Identify ( Remove White Triplesfrom Binary2 to Binary3 ) Display ( Image0 (on), frames (on,on), planes(off,off,off,3,off,off), lut 0, x 0, y 0, z 1, Reduction off ) MEASUREFIELD ANISOTROPY PauseText ( “Set measure frame region now.” ) Measureframe [PAUSE] ( x 1296, y 255, Width 506, Height 497 ) MFLDIMAGE = 3Measure field ( plane MFLDIMAGE, into FLDRESULTS(1), statistics intoFLDSTATS(7,1) ) Selected parameters: Anisotropy ANISOT = FLDRESULTS(1)MEASURE FEATURE ORIENTATION Clear Accepts Measure feature ( planeBinary3, 64 ferets, minimum area: 10, grey image: Image0 ) Selectedparameters: X FCP, Y FCP, VertProj, HorizProj, Length, Perimeter,UserDef1, UserDef2, DerivOrient Feature Expression ( UserDef1 ( allfeatures ), title Orient = PHPROJ(FTR)/PVPROJ(FTR) ) Feature Expression( UserDef2 ( all features ), title Length = PPERIMETER(FTR)/2 ) FeatureHistogram #1 ( Y Param UserDef2, X Param DerivOrient, from 0. to 180.,linear, 20 bins ) Feature Histogram #2 ( Y Param UserDef2, X ParamUserDef1, from 1,999999955e−002 to 200., logarithmic, 20 bins ) DisplayFeature Histogram Results ( #1, horizontal, differential, bins + graph(Y axis linear), statistics ) Data Window ( 1336, 117, 341, 454 )Display Feature Histogram Results ( #2, horizontal, differential, bins +graph (Y axis linear), statistics ) Data Window ( 1329, 566, 341, 454 )-- Output data to spreadsheet File Feature Histogram Results ( #1,differential, statistics, bin details, channel #1 ) File Line ( channel#1 ) File Line ( channel #1 ) File Feature Histogram Results ( #2,differential, statistics, bin details, channel #1 ) File Line ( channel#1 ) File Line ( channel #1 ) File ( “Anisotropy = ”, channel #1 ) File( ANISOT, channel #1, 3 digits after ‘.’ ) File Line ( channel #1 ) FileLine ( channel #1 ) File Line ( channel #1 )  Next ( FIELD )  Close File( channel #1 )

The QUIPS algorithm is executed using the QWIN Pro software platform.The analyst is initially prompted to enter the number of images in theset for a particular specimen. Next, the analyst is prompted to enterspecimen identification information which is sent to the EXCEL file.

The analyst is next prompted by an interactive command window and aninput window to enter the image file prefix of the Micro-CT images to beanalyzed. After this step, all subsequent images for a given sample willbe read automatically by the image analysis algorithm described above.

The analyst is next prompted to manually select, with the computermouse, the connecting ligament region of interest for analysis. Careshould be taken to select only the connecting ligament of interest.

After several steps of image processing that will occur automatically,the analyst will again be prompted to clean up any over-extended regionof interest (ROI) areas. This is done using the computer mouse as wellas toggling the overlying binary image on and off by simultaneouslyusing the ‘control’ and ‘b’ keys on the computer keyboard. After thisstep, the binary should only be covering the connecting ligament.

The process of selecting the connecting ligament 14 region of interestand clean up of over-extended regions will repeat until all the imagesfor a particular specimen have been analyzed.

After all images have been analyzed, the following measurement parameterdata will be located in the corresponding EXCEL file:

Replicate # Anisotropy

There will be 6 values listed in columns for the Anisotropy parameter.For the purposes of comparing anisotropy values between connectingligaments 14 which connect longitudinally adjacent nodes 12 andconnecting ligaments 14 which connect laterally adjacent nodes 12, thedata in the column labeled ‘Anisotropy’ can be compared betweendifferent specimens by performing a Student's T analysis at the 90%confidence level.

EMBODIMENTS

Embodiment 1: In a first embodiment, a nonwoven material may comprise aplurality of fibers and may extend between a first end and a second end,the nonwoven material having a material width and may further comprise afirst surface and a second surface, the first surface being oppositefrom the second surface, an apertured zone comprising: a plurality ofnodes extending away from a base plane on the first surface, a pluralityof connecting ligaments interconnecting the plurality of nodes, whereina majority of the plurality of nodes include at least three connectingligaments connecting to adjacent nodes, and a plurality of openingsproviding a percent open area for the apertured zone of the nonwovenmaterial that is greater than about 15%, as determined by the MaterialSample Analysis Test Method; a first side zone and a second side zone,the first side zone having a first side zone width and the second sidezone having a second side zone width, and wherein each of the first sidezone width and the second side zone width may be between about 5% andabout 25% of the nonwoven material width.Embodiment 2: In a second embodiment, each of the first side zone widthand the second side zone width of embodiment 1 may be between about 5%and about 15% of the nonwoven material width.Embodiment 3: In a third embodiment, the value of the first side zonewidth of any one of the embodiments 1 or 2 may be within about 25% ofthe value of the second side zone width.Embodiment 4: In a fourth embodiment, the plurality of openings of anyone of the embodiments 1-3 may provide a percent open area for theapertured zone of the nonwoven material that is greater than about 20%,as determined by the Material Sample Analysis Test Method.Embodiment 5: In a fifth embodiment, the first side zone and the secondside zone of any one of the embodiments 1˜4 may each have a percent openarea greater than about 0.5% and less about 10%, as determined by theMaterial Sample Analysis Test Method.Embodiment 6: In a sixth embodiment, the apertured zone of any one ofthe embodiments 1-5 may have a Poisson's ratio that is less than about 3at 1% strain, as determined by the Poisson's Ratio Test Method.Embodiment 7: In a seventh embodiment, the first side zone and thesecond side zone of any one of the embodiments 1-6 may each extendbetween the first end of the nonwoven material and the second end of thenonwoven material.Embodiment 8: In an eighth embodiment, a nonwoven material may comprisea plurality of fibers and may extend between a first end and a secondend and may further comprise an apertured zone, the apertured zonecomprising a plurality of openings providing a percent open area for theapertured zone of the nonwoven material that is greater than about 15%,as determined by the Material Sample Analysis Test Method; and a firstside zone and a second side zone, each of the first side zone and thesecond side zone having a percent open area greater than about 0.5% andless than the percent open area of the apertured zone, as determined bythe Material Sample Analysis Test Method, wherein a ratio of a tensilestrength of the first side zone plus a tensile strength of the secondside zone divided by a tensile strength of the apertured zone may bebetween about 0.8 and about 2.5.Embodiment 9: In a ninth embodiment, the ratio of the tensile strengthof the first side zone plus the second side zone divided by theapertured zone of embodiment 8 may be between about 0.8 and about 1.75Embodiment 10: In a tenth embodiment, the apertured zone of any one ofembodiment 8 or 9 may further comprise a plurality of nodes extendingaway from a base plane on the first surface and a plurality ofconnecting ligaments interconnecting the plurality of nodes, wherein amajority of the plurality of nodes may include at least three connectingligaments connecting to adjacent nodes.Embodiment 11: In an eleventh embodiment, each connecting ligament ofembodiment 10 may extend between only two adjacent nodes.Embodiment 12: In a twelfth embodiment, the plurality of openings of anyone of the embodiments 8-11 may provide a percent open area for theapertured zone of the nonwoven material that is greater than about 20%,as determined by the Material Sample Analysis Test Method.Embodiment 13: In a thirteenth embodiment, the nonwoven material of anyone of embodiments 8-12 may have a material width and the first sidezone has a first side zone width and the second side zone has a secondside zone width, and wherein each of the first side zone width and thesecond side zone width may be between about 5% and about 25% of thenonwoven material width.Embodiment 14: In a fourteenth embodiment, the first side zone and thesecond side zone of any one of embodiments 8-13 may have a first sidezone width and a second side zone width, and wherein the value of thefirst side zone width may be within about 50% of the value of the secondside zone width.Embodiment 15: In a fifteenth embodiment, a nonwoven material maycomprise a plurality of fibers and may extend between a first end and asecond end and may further comprise an apertured zone, the aperturedzone comprising a plurality of openings providing a percent open areafor the apertured zone of the nonwoven material that is greater thanabout 15%, as determined by the Material Sample Analysis Test Method,and a first side zone and a second side zone, each of the first sidezone and the second side zone having a percent open area greater thanabout 0.5% and less than the percent open area of the apertured zone, asdetermined by the Material Sample Analysis Test Method, wherein aPoisson's ratio of the apertured zone of the nonwoven material is lessthan about 3 at 1% strain, as determined by the Poisson's Ratio TestMethod.Embodiment 16: In a sixteenth embodiment, the Poisson's ratio of theapertured zone of the nonwoven material of embodiment 15 may be lessthan about 2 at 1% strain, as determined by the Poisson's Ratio TestMethod.Embodiment 17: In a seventeenth embodiment, the apertured zone of anyone of embodiment 15 or 16 may further comprise a plurality of nodesextending away from a base plane on the first surface and a plurality ofconnecting ligaments interconnecting the plurality of nodes, wherein amajority of the plurality of nodes include at least three connectingligaments connecting to adjacent nodes.Embodiment 18: In an eighteenth embodiment, wherein each connectingligament of embodiment 17 may extend between only two adjacent nodesEmbodiment 19: In a nineteenth embodiment, the plurality of openings ofany one of the embodiments 15-18 may provide a percent open area for theapertured zone of the nonwoven material that is greater than about 20%,as determined by the Material Sample Analysis Test Method.Embodiment 20: In a twentieth embodiment, the nonwoven material of anyone of the embodiments 15-19 may have a material width and the firstside zone may have a first side zone width and the second side zone mayhave a second side zone width, and wherein each of the first side zonewidth and the second side zone width may be between about 5% and about25% of the nonwoven material width.

All documents cited in the Detailed Description are, in relevant part,incorporated herein by reference; the citation of any document is not tobe construed as an admission that it is prior art with respect to thepresent invention. To the extent that any meaning or definition of aterm in this written document conflicts with any meaning or definitionof the term in a document incorporated by references, the meaning ordefinition assigned to the term in this written document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A nonwoven material comprising a plurality offibers and extending between a first end and a second end, the nonwovenmaterial having a material width and comprising: a first surface and asecond surface, the first surface being opposite from the secondsurface; an apertured zone, the apertured zone comprising: a pluralityof nodes extending away from a base plane on the first surface, aplurality of connecting ligaments interconnecting the plurality ofnodes, wherein a majority of the plurality of nodes include at leastthree connecting ligaments connecting to adjacent nodes, and a pluralityof openings providing a percent open area for the apertured zone of thenonwoven material that is greater than about 15%, as determined by theMaterial Sample Analysis Test Method; and a first side zone and a secondside zone, the first side zone having a first side zone width and thesecond side zone having a second side zone width, and wherein each ofthe first side zone width and the second side zone width are betweenabout 5% and about 25% of the nonwoven material width.
 2. The nonwovenmaterial of claim 1, wherein each of the first side zone width and thesecond side zone width are between about 5% and about 15% of thenonwoven material width.
 3. The nonwoven material of claim 1, andwherein the value of the first side zone width is within about 25% ofthe value of the second side zone width.
 4. The nonwoven material ofclaim 1, wherein the plurality of openings provide a percent open areafor the apertured zone of the nonwoven material that is greater thanabout 20%, as determined by the Material Sample Analysis Test Method. 5.The nonwoven material of claim 1, wherein the first side zone and thesecond side zone each have a percent open area greater than about 0.5%and less about 10%, as determined by the Material Sample Analysis TestMethod.
 6. The nonwoven material of claim 1, wherein a Poisson's ratioof the apertured zone of the nonwoven material is less than about 3 at1% strain, as determined by the Poisson's Ratio Test Method.
 7. Thenonwoven material of claim 1, wherein the first side zone and the secondside zone each extend between the first end of the nonwoven material andthe second end of the nonwoven material.
 8. A nonwoven materialcomprising a plurality of fibers and extending between a first end and asecond end, the nonwoven material comprising: an apertured zone, theapertured zone comprising a plurality of openings providing a percentopen area for the apertured zone of the nonwoven material that isgreater than about 15%, as determined by the Material Sample AnalysisTest Method; and a first side zone and a second side zone, each of thefirst side zone and the second side zone having a percent open areagreater than about 0.5% and less than the percent open area of theapertured zone, as determined by the Material Sample Analysis TestMethod, wherein a ratio of a tensile strength of the first side zoneplus a tensile strength of the second side zone divided by a tensilestrength of the apertured zone is between about 0.8 and about 2.5. 9.The nonwoven material of claim 8, wherein the ratio of the tensilestrength of the first side zone plus the second side zone divided by theapertured zone is between about 0.8 and about 1.75.
 10. The nonwovenmaterial of claim 8, wherein the apertured zone further comprises aplurality of nodes extending away from a base plane on the first surfaceand a plurality of connecting ligaments interconnecting the plurality ofnodes, wherein a majority of the plurality of nodes include at leastthree connecting ligaments connecting to adjacent nodes.
 11. Thenonwoven material of claim 10, wherein each connecting ligament extendsbetween only two adjacent nodes.
 12. The nonwoven material of claim 8,wherein the plurality of openings provide a percent open area for theapertured zone of the nonwoven material that is greater than about 20%,as determined by the Material Sample Analysis Test Method.
 13. Thenonwoven material of claim 8, wherein the nonwoven material has amaterial width and the first side zone has a first side zone width andthe second side zone has a second side zone width, and wherein each ofthe first side zone width and the second side zone width are betweenabout 5% and about 25% of the nonwoven material width.
 14. The nonwovenmaterial of claim 8, wherein the first side zone has a first side zonewidth and the second side zone has a second side zone width, and whereinthe value of the first side zone width is within about 50% of the valueof the second side zone width.
 15. A nonwoven material comprising aplurality of fibers and extending between a first end and a second end,the nonwoven material comprising: an apertured zone, the apertured zonecomprising a plurality of openings providing a percent open area for theapertured zone of the nonwoven material that is greater than about 15%,as determined by the Material Sample Analysis Test Method; and a firstside zone and a second side zone, each of the first side zone and thesecond side zone having a percent open area greater than about 0.5% andless than the percent open area of the apertured zone, as determined bythe Material Sample Analysis Test Method, wherein a Poisson's ratio ofthe apertured zone of the nonwoven material is less than about 3 at 1%strain, as determined by the Poisson's Ratio Test Method.
 16. Thenonwoven material of claim 15, wherein the Poisson's ratio of theapertured zone of the nonwoven material is less than about 2 at 1%strain, as determined by the Poisson's Ratio Test Method.
 17. Thenonwoven material of claim 15, wherein the apertured zone furthercomprises a plurality of nodes extending away from a base plane on thefirst surface and a plurality of connecting ligaments interconnectingthe plurality of nodes, wherein a majority of the plurality of nodesinclude at least three connecting ligaments connecting to adjacentnodes.
 18. The nonwoven material of claim 17, wherein each connectingligament extends between only two adjacent nodes
 19. The nonwovenmaterial of claim 15, wherein the plurality of openings provide apercent open area for the apertured zone of the nonwoven material thatis greater than about 20%, as determined by the Material Sample AnalysisTest Method.
 20. The nonwoven material of claim 15, wherein the nonwovenmaterial has a material width and the first side zone has a first sidezone width and the second side zone has a second side zone width, andwherein each of the first side zone width and the second side zone widthare between about 5% and about 25% of the nonwoven material width.